US20150083322A1 - Idle Air Control Valve With Plastic Housing And Retention Features - Google Patents
Idle Air Control Valve With Plastic Housing And Retention Features Download PDFInfo
- Publication number
- US20150083322A1 US20150083322A1 US14/514,528 US201414514528A US2015083322A1 US 20150083322 A1 US20150083322 A1 US 20150083322A1 US 201414514528 A US201414514528 A US 201414514528A US 2015083322 A1 US2015083322 A1 US 2015083322A1
- Authority
- US
- United States
- Prior art keywords
- plastic housing
- stator assembly
- connector structure
- housing
- plastic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D31/00—Use of speed-sensing governors to control combustion engines, not otherwise provided for
- F02D31/001—Electric control of rotation speed
- F02D31/002—Electric control of rotation speed controlling air supply
- F02D31/003—Electric control of rotation speed controlling air supply for idle speed control
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M3/00—Idling devices for carburettors
- F02M3/08—Other details of idling devices
- F02M3/09—Valves responsive to engine conditions, e.g. manifold vacuum
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
- F16K31/06—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
- F16K31/0644—One-way valve
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
- F16K31/06—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
- F16K31/08—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid using a permanent magnet
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K99/00—Subject matter not provided for in other groups of this subclass
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/14—Casings; Enclosures; Supports
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/08—Insulating casings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
- H02K7/06—Means for converting reciprocating motion into rotary motion or vice versa
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/0318—Processes
- Y10T137/0402—Cleaning, repairing, or assembling
- Y10T137/0491—Valve or valve element assembling, disassembling, or replacing
Definitions
- This invention relates to a linear actuator such as a vehicle idle air control valve (IACV) and, more particularly, to an improved IACV having a plastic housing and retention features.
- IACV vehicle idle air control valve
- the IACV is a digital linear actuator (DLA) mounted externally to the intake manifold of automotive engines that accurately controls throttle airflow in an engine system. Axial alignment of the IACV ensures that a pintle/capnut thereof maintains proper alignment with a throttle body or manifold valve seat.
- DLA digital linear actuator
- the conventional IACV is an automotive grade can-stack style stepper motor which has been in production for 10-15 years.
- the conventional IACV has a metal housing for stringent environmental standards requiring that Hexavalent (Cr6) plating replaced by Trivalent (Cr3) plating. This housing met the environmental standards but failed to provide sufficient duration for corrosion protection which may result in a cosmetic annoyance to end customers.
- a linear actuator including a plastic housing having an integral flange for mounting the actuator.
- a stator assembly is disposed in the plastic housing, with the stator assembly having windings.
- a rotor assembly having a permanent magnet, is mounted for rotation with respect to the stator assembly such that when the windings are energized, a magnetic field is generated to cause rotation of the rotor assembly.
- a shaft is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft.
- Connector structure houses leads for powering the windings.
- the plastic housing has an annular end that captures an annular surface of the connector structure coupling the plastic housing to the connector structure.
- an idle air control valve for a vehicle includes a plastic housing having an integral flange for mounting the actuator.
- a stator assembly is disposed in the plastic housing with the stator assembly having windings.
- a rotor assembly having a permanent magnet, is mounted for rotation with respect to the stator assembly such that when the windings are energized, a magnetic field is generated to cause rotation of the rotor assembly.
- a shaft is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft.
- a pintle is associated with a distal end of the shaft for linear movement therewith.
- Connector structure houses leads for powering the windings.
- the plastic housing has an annular end that captures an annular surface of the connector structure, coupling the plastic housing to the connector structure.
- a method provides a plastic housing for an actuator.
- the actuator has a stator assembly coupled to a connector structure, and a rotor assembly constructed and arranged to rotate with respect to the stator assembly.
- the method includes inserting the stator assembly with connector structure connected thereto into an interior of the plastic housing until a surface of the stator assembly engages a surface of the plastic housing, with an annular end of the plastic housing extending beyond an adjacent annular surface of the connector structure. The annular end of the housing is then deformed to capture the annular surface of the connector structure, thereby coupling the plastic housing to the connector structure.
- FIG. 1 is an axial sectional view of an embodiment of a digital linear actuator in the form of an idle air control valve (IACV) in accordance with an embodiment of the invention.
- IACV idle air control valve
- FIG. 2 is view of a portion of an end of a plastic housing of the IACV prior to heat forming thereof.
- FIG. 3 is a view of a portion of the end of the plastic housing of FIG. 2 , shown after heat rolling to capture a portion of a connector structure.
- FIG. 4 is a partial sectional view of the end of the plastic housing prior to heat rolling thereof.
- FIG. 5 is a partial sectional view of the end of the plastic housing after heat rolling and shown capturing a portion of the connection structure.
- FIG. 6 is a view of the plastic housing of the IACV showing tabs of anti-rotate structure.
- FIG. 7 is a view showing the anti-rotate structure with a tab engaged in a pocket of the stator assembly of the IACV.
- a motor, generalty indicated at 10 of an Idle Air Control Valve (IACV) for use in a vehicle is shown in accordance with an embodiment of the present invention.
- the motor 10 includes a plastic housing 12 with integral flange 14 extending outwardly of the housing 12 .
- a stator assembly, generally indicated at 16 is disposed in the housing 12 .
- the stator assembly 16 includes the conventional windings 18 , field cups, pole plates, and bobbins.
- a rotor assembly is associated with the stator assembly 16 .
- the rotor assembly 20 has the conventional permanent magnet 22 generally adjacent to the windings 18 .
- Bearing structure including a rear, sealed ball bearing 24 and a front eyelet bearing 26 supports the rotor assembly 20 to permit rotation of the rotor assembly 20 relative to the stator assembly 16 .
- introduction of a current in the coil windings 18 of the stator assembly 16 causes rotational movement of the rotor assembly 20 .
- the rotor assembly 20 has a passage 28 there-through including a threaded portion 30 for engagement with a threaded portion of shaft 32 .
- the distal end of the shaft 32 is associated with a front bearing 33 , preventing shaft rotation. Therefore, rotational motion of rotor assembly 20 is converted into linear motion of shaft 32 , making this stepper motor a linear actuator.
- the shaft 32 has an integral pintle 34 at its distal end.
- a spring 36 tends to bias the pintle 34 in an extended position.
- the pintle 34 receives a cylindrical grime shield 38 to protect against contamination of the motor 10 .
- the motor 10 can be fitted within a bore of an intake manifold or throttle body. To control airflow into the manifold.
- the flux ring structure 40 includes a pair of ferrous material flux rings disposed about the stator assembly 16 , generally adjacent to the windings 18 .
- the flange 14 provides bolt holes 42 there-through for the mounting hardware to the manifold. Since the material of the flange 14 is plastic (instead of metal), M4 and M5 mounting bolts could damage the plastic flange 14 when torqued to the prescribed installation torque. Thus, metal, preferably split-ring compression limiters 44 are provided in the bolt holes 42 to prevent damage to the flange 14 . The limiters 44 frictionally engage the surfaces defining the bolt holes 42 .
- An important retention feature of the motor 10 is heat rolling of the plastic housing 12 to capture a connector structure 46 of the motor 10 and thus capture the stator assembly 16 and rotor assembly 20 that are coupled to the connector structure 46 .
- the connector structure houses leads 47 ( FIG. 4 ) for powering the windings 18 in the conventional manner.
- Alternative methods of coupling the plastic housing 12 to the connector structure 46 were attempted. For example, molding snap fingers on the inner surface of the housing 12 was not possible. Further, ultrasonic welding of the core of the motor 10 to a plastic housing 12 had mixed results. After thermal cycling, the ultrasonic weld retention load was compromised. Secondary, contamination of the ultrasonic weld surfaces were found unpredictable. Thus, the heat rolling process, explained below, was developed.
- the connector structure 46 is inserted axially into the interior 49 of the plastic housing 12 until a planar surface 51 of the stator assembly 16 contacts a planar surface 53 ( FIG. 4 ) of the plastic housing 12 .
- a distal, annular end 48 of the housing 12 extends beyond an annular surface 50 of the connector structure 46 .
- a heat rolling process heats and deforms the end 48 to capture the annular surface 50 ( FIGS. 1 , 3 and 5 ) of the connector structure 46 thereby coupling the plastic housing 12 to the connector structure 46 .
- This heat deformation process of the plastic housing 12 functionally replicates a swaged metal housing.
- the end 48 is deformed to have a radius R of approximately 1.9 mm.
- the heat roll formation of the plastic is more difficult than the conventional metal swage.
- Functional requirements for the heat roll connection are, a static 90 N axial load test and also to retain structural integrity after thermal life cycling and thermal vibration.
- the plastic housing 12 provides sufficient flexure that ensures alignment throughout the range of thermal exposure (e.g., ⁇ 40 to +125C manifold ambient environment). This flexure, in addition to axial support, provides additional tolerance to manifold vibration since excess vibration can damage the internal motor of the IACV.
- the heat roll connection between the housing 12 and the connector structure 46 can be air leak tested as witnessed by IACV on the engine manifold.
- FIG. 6 Another important retention feature of the motor 10 is anti-rotate structure created between the plastic housing 12 and the stator assembly 16 .
- a plurality of tabs 52 preferably molded into the hosing 12 , extend in spaced relation about an interior surface 54 of the plastic housing 12 .
- the stator assembly 16 includes a plurality of pockets 56 , with one pocket 56 being associated with one tab 52 .
- each tab 52 engages an associated pocket 56 .
- the configuration is such that the interference between the pocket 56 and tab 52 is sufficient that the plastic of the tabs 52 and plastic of the surfaces defining the pocket 56 yield or deform creating a tongue and groove anti-rotate interlock structure.
- the functional requirement for this anti-rotate structure is a 5.5 N-m resistance of the core of the motor turning without violating the angle location requirement of the electrical connector of the connector structure 46 .
- the plastic used for the housing can by any plastic material suitable for the environment of an idle air control valve.
- Features of the plastic housing 12 include:
Abstract
A method provides a plastic housing for an actuator. The actuator has a stator assembly coupled to a connector structure and a rotor assembly that rotates with respect to the stator assembly. The method inserts the stator assembly with connector structure connected thereto into an interior of the plastic housing until a surface of the stator assembly engages a surface of the plastic housing, with an annular end of the plastic housing extending beyond an adjacent annular surface of the connector structure. The annular end of the housing is heated and deformed to capture the annular surface of the connector structure, thereby coupling the plastic housing to the connector structure.
Description
- This application claims the benefit of the earlier filing date of U.S. Provisional Application No. 61/326,757, filed on Apr. 22, 2010, which is hereby incorporated by reference into this specification.
- This invention relates to a linear actuator such as a vehicle idle air control valve (IACV) and, more particularly, to an improved IACV having a plastic housing and retention features.
- The IACV is a digital linear actuator (DLA) mounted externally to the intake manifold of automotive engines that accurately controls throttle airflow in an engine system. Axial alignment of the IACV ensures that a pintle/capnut thereof maintains proper alignment with a throttle body or manifold valve seat. The IACV is needed since vehicle pollution emission control regulations require more precise air/fuel ratios and thus cleaner tailpipe emissions.
- The conventional IACV is an automotive grade can-stack style stepper motor which has been in production for 10-15 years. The conventional IACV has a metal housing for stringent environmental standards requiring that Hexavalent (Cr6) plating replaced by Trivalent (Cr3) plating. This housing met the environmental standards but failed to provide sufficient duration for corrosion protection which may result in a cosmetic annoyance to end customers.
- Thus, there is a need to provide an improved IACV having a plastic housing that will meet warranty requirements and that can provide a measure of cosmetic appeal due to use of non-corrosive materials.
- An object of the invention is to fulfill the need referred to above. In accordance with the principles of the present invention, this objective is obtained by providing a linear actuator including a plastic housing having an integral flange for mounting the actuator. A stator assembly is disposed in the plastic housing, with the stator assembly having windings. A rotor assembly, having a permanent magnet, is mounted for rotation with respect to the stator assembly such that when the windings are energized, a magnetic field is generated to cause rotation of the rotor assembly. A shaft is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. Connector structure houses leads for powering the windings. The plastic housing has an annular end that captures an annular surface of the connector structure coupling the plastic housing to the connector structure.
- In accordance with another aspect of the invention, an idle air control valve for a vehicle includes a plastic housing having an integral flange for mounting the actuator. A stator assembly is disposed in the plastic housing with the stator assembly having windings. A rotor assembly, having a permanent magnet, is mounted for rotation with respect to the stator assembly such that when the windings are energized, a magnetic field is generated to cause rotation of the rotor assembly. A shaft is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. A pintle is associated with a distal end of the shaft for linear movement therewith. Connector structure houses leads for powering the windings. The plastic housing has an annular end that captures an annular surface of the connector structure, coupling the plastic housing to the connector structure.
- In accordance with yet another aspect of the invention, a method provides a plastic housing for an actuator. The actuator has a stator assembly coupled to a connector structure, and a rotor assembly constructed and arranged to rotate with respect to the stator assembly. The method includes inserting the stator assembly with connector structure connected thereto into an interior of the plastic housing until a surface of the stator assembly engages a surface of the plastic housing, with an annular end of the plastic housing extending beyond an adjacent annular surface of the connector structure. The annular end of the housing is then deformed to capture the annular surface of the connector structure, thereby coupling the plastic housing to the connector structure.
- Other objects, features and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure, the combination of parts and economics of manufacture will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification.
- The invention will be better understood from the following detailed description of the preferred embodiments thereof, taken in conjunction with the accompanying drawing, wherein like reference numerals refer to like parts, in which:
-
FIG. 1 is an axial sectional view of an embodiment of a digital linear actuator in the form of an idle air control valve (IACV) in accordance with an embodiment of the invention. -
FIG. 2 is view of a portion of an end of a plastic housing of the IACV prior to heat forming thereof. -
FIG. 3 is a view of a portion of the end of the plastic housing ofFIG. 2 , shown after heat rolling to capture a portion of a connector structure. -
FIG. 4 is a partial sectional view of the end of the plastic housing prior to heat rolling thereof. -
FIG. 5 is a partial sectional view of the end of the plastic housing after heat rolling and shown capturing a portion of the connection structure. -
FIG. 6 is a view of the plastic housing of the IACV showing tabs of anti-rotate structure. -
FIG. 7 is a view showing the anti-rotate structure with a tab engaged in a pocket of the stator assembly of the IACV. - For illustrative purposes, throughout the following discussion the invention is described as it is incorporated into a particular magnetic device used in a specific product assembly, namely an electric motor, generally indicated at 10, in the form of a stepper motor that provides linear actuation for an idle air
control valve assembly 11 for a vehicle. However, the invention is equally applicable to other linear actuator devices that are employed in harsh environment. - With reference to
FIG. 1 , a motor, generalty indicated at 10, of an Idle Air Control Valve (IACV) for use in a vehicle is shown in accordance with an embodiment of the present invention. Themotor 10 includes aplastic housing 12 withintegral flange 14 extending outwardly of thehousing 12. A stator assembly, generally indicated at 16, is disposed in thehousing 12. Thestator assembly 16 includes theconventional windings 18, field cups, pole plates, and bobbins. - As shown in
FIG. 1 , a rotor assembly, generally indicated at 20, is associated with thestator assembly 16. Therotor assembly 20 has the conventionalpermanent magnet 22 generally adjacent to thewindings 18. Bearing structure, including a rear, sealed ball bearing 24 and afront eyelet bearing 26 supports therotor assembly 20 to permit rotation of therotor assembly 20 relative to thestator assembly 16. In the embodiment ofmotor 10 as a stepper motor, introduction of a current in thecoil windings 18 of thestator assembly 16 causes rotational movement of therotor assembly 20. Therotor assembly 20 has apassage 28 there-through including a threadedportion 30 for engagement with a threaded portion ofshaft 32. The distal end of theshaft 32 is associated with a front bearing 33, preventing shaft rotation. Therefore, rotational motion ofrotor assembly 20 is converted into linear motion ofshaft 32, making this stepper motor a linear actuator. - In the embodiment of the
motor 10 used in an idle air control valve, theshaft 32 has anintegral pintle 34 at its distal end. Aspring 36 tends to bias thepintle 34 in an extended position. Thepintle 34 receives acylindrical grime shield 38 to protect against contamination of themotor 10. With the example of the idle air control valve shown inFIG. 1 , themotor 10 can be fitted within a bore of an intake manifold or throttle body. To control airflow into the manifold. - Since the housing is made of plastic instead of metal, to ensure that the flux path is not disrupted, additional, compensating
flux ring structure 40 is provided at the perimeter of thestator assembly 16. In the embodiments theflux ring structure 40 includes a pair of ferrous material flux rings disposed about thestator assembly 16, generally adjacent to thewindings 18. - The
flange 14 providesbolt holes 42 there-through for the mounting hardware to the manifold. Since the material of theflange 14 is plastic (instead of metal), M4 and M5 mounting bolts could damage theplastic flange 14 when torqued to the prescribed installation torque. Thus, metal, preferably split-ring compression limiters 44 are provided in thebolt holes 42 to prevent damage to theflange 14. Thelimiters 44 frictionally engage the surfaces defining thebolt holes 42. - An important retention feature of the
motor 10 is heat rolling of theplastic housing 12 to capture aconnector structure 46 of themotor 10 and thus capture thestator assembly 16 androtor assembly 20 that are coupled to theconnector structure 46. The connector structure houses leads 47 (FIG. 4 ) for powering thewindings 18 in the conventional manner. Alternative methods of coupling theplastic housing 12 to theconnector structure 46 were attempted. For example, molding snap fingers on the inner surface of thehousing 12 was not possible. Further, ultrasonic welding of the core of themotor 10 to aplastic housing 12 had mixed results. After thermal cycling, the ultrasonic weld retention load was compromised. Secondary, contamination of the ultrasonic weld surfaces were found unpredictable. Thus, the heat rolling process, explained below, was developed. - In accordance with the embodiment and with reference to
FIGS. 2-4 , theconnector structure 46 is inserted axially into the interior 49 of theplastic housing 12 until aplanar surface 51 of thestator assembly 16 contacts a planar surface 53 (FIG. 4 ) of theplastic housing 12. As seen inFIGS. 2 and 4 , after such insertion, a distal,annular end 48 of thehousing 12 extends beyond anannular surface 50 of theconnector structure 46. Thereafter, a heat rolling process heats and deforms theend 48 to capture the annular surface 50 (FIGS. 1 , 3 and 5) of theconnector structure 46 thereby coupling theplastic housing 12 to theconnector structure 46. This heat deformation process of theplastic housing 12 functionally replicates a swaged metal housing. Thus, in the embodiment, theend 48 is deformed to have a radius R of approximately 1.9 mm. - The heat roll formation of the plastic is more difficult than the conventional metal swage. Functional requirements for the heat roll connection are, a static 90 N axial load test and also to retain structural integrity after thermal life cycling and thermal vibration. The
plastic housing 12 provides sufficient flexure that ensures alignment throughout the range of thermal exposure (e.g., −40 to +125C manifold ambient environment). This flexure, in addition to axial support, provides additional tolerance to manifold vibration since excess vibration can damage the internal motor of the IACV. The heat roll connection between thehousing 12 and theconnector structure 46 can be air leak tested as witnessed by IACV on the engine manifold. - Another important retention feature of the
motor 10 is anti-rotate structure created between theplastic housing 12 and thestator assembly 16. As seen inFIG. 6 , a plurality oftabs 52, preferably molded into the hosing 12, extend in spaced relation about aninterior surface 54 of theplastic housing 12. As shown inFIG. 7 , thestator assembly 16 includes a plurality ofpockets 56, with onepocket 56 being associated with onetab 52. Thus, upon assembly of thehousing 12 with thestator assembly 16, eachtab 52 engages an associatedpocket 56. The configuration is such that the interference between thepocket 56 andtab 52 is sufficient that the plastic of thetabs 52 and plastic of the surfaces defining thepocket 56 yield or deform creating a tongue and groove anti-rotate interlock structure. The functional requirement for this anti-rotate structure is a 5.5 N-m resistance of the core of the motor turning without violating the angle location requirement of the electrical connector of theconnector structure 46. - The plastic used for the housing can by any plastic material suitable for the environment of an idle air control valve. Features of the
plastic housing 12 include: -
- unique external heat forming the
plastic housing end 48 after assembly to retain the core motor - external heat form allows for 360° connector orientation with respect to the
housing 12 whereas conventional internal snap retention configurations are location sensitive - heat form method less expensive solution to ultrasonic welding with existing jointing issues
- molded internal anti-rotation interlock structure
- flange/housing integration eliminates existing jointing issues
- flange compression limiters allow use of existing hardware (manifold)
- weight savings
- the plastic housing exterior eliminates corrosion plating and associated cosmetics rejects
- motor efficiency is higher due to provision of the flux ring structure
- utilizes existing production core motor with minimal refinements
- unique external heat forming the
- The foregoing preferred embodiments have been shown and described for the purposes of illustrating the structural and functional principles of the present invention, as well as illustrating the methods of employing the preferred embodiments and are subject to change without departing from such principles. Therefore, this invention includes all modifications encompassed within the spirit of the following claims.
Claims (7)
1-10. (canceled)
11. A method of providing a plastic housing for an actuator, the actuator having a stator assembly coupled to a connector structure, and a rotor assembly constructed and arranged to rotate with respect to the stator assembly, the method comprising the steps of:
inserting the stator assembly with connector structure connected thereto into an interior of the plastic housing until a surface of the stator assembly engages a surface of the plastic housing, with an annular end of the plastic housing extending beyond an adjacent annular surface of the connector structure, and
heating and deforming the annular end of the housing to capture the annular surface of the connector structure, thereby coupling the plastic housing to the connector structure.
12. The method of claim 11 , wherein the deforming step includes rolling the heated annular end of the plastic housing.
13. The method of claim 11 , further comprising:
providing tabs in the interior of the plastic housing and providing associated pockets in the stator assembly such that upon the inserting step, a tab interlocks with an associated pocket, thereby preventing rotation of the stator assembly with respect to the plastic housing.
14. The method of claim 11 , wherein the plastic housing includes an integral flange, the flange including bolt holes there-through, the method further comprising:
inserting a metal compression limiter in each bolt hole.
15. The method of claim 11 , wherein prior to the inserting step, the method further comprises:
providing ferrous flux ring structure about a portion of the stator assembly.
16. The method of claim 11 , wherein prior to the deforming step, the method further comprises:
orienting the connector structure to one of 360° positions with respect to the annular wall of the plastic housing.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US14/514,528 US20150083322A1 (en) | 2010-04-22 | 2014-10-15 | Idle Air Control Valve With Plastic Housing And Retention Features |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US32675710P | 2010-04-22 | 2010-04-22 | |
PCT/US2011/031270 WO2011133320A2 (en) | 2010-04-22 | 2011-04-05 | Idle air control valve with plastic housing and retention features |
US201313642677A | 2013-01-17 | 2013-01-17 | |
US14/514,528 US20150083322A1 (en) | 2010-04-22 | 2014-10-15 | Idle Air Control Valve With Plastic Housing And Retention Features |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US13/642,677 Division US9144936B2 (en) | 2010-04-22 | 2011-04-05 | Idle air control valve with plastic housing and retention features |
PCT/US2011/031270 Division WO2011133320A2 (en) | 2010-04-22 | 2011-04-05 | Idle air control valve with plastic housing and retention features |
Publications (1)
Publication Number | Publication Date |
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US20150083322A1 true US20150083322A1 (en) | 2015-03-26 |
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ID=44625789
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US13/642,677 Expired - Fee Related US9144936B2 (en) | 2010-04-22 | 2011-04-05 | Idle air control valve with plastic housing and retention features |
US14/514,528 Abandoned US20150083322A1 (en) | 2010-04-22 | 2014-10-15 | Idle Air Control Valve With Plastic Housing And Retention Features |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US13/642,677 Expired - Fee Related US9144936B2 (en) | 2010-04-22 | 2011-04-05 | Idle air control valve with plastic housing and retention features |
Country Status (8)
Country | Link |
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US (2) | US9144936B2 (en) |
EP (1) | EP2561600B1 (en) |
JP (1) | JP5575329B2 (en) |
KR (1) | KR101812715B1 (en) |
CN (1) | CN102844967B (en) |
AU (1) | AU2011243111B2 (en) |
MX (1) | MX2012012249A (en) |
WO (1) | WO2011133320A2 (en) |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
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KR101812715B1 (en) * | 2010-04-22 | 2017-12-27 | 컨티넨탈 오토모티브 시스템즈 인코포레이티드 | Idle air control valve with plastic housing and retention features |
CN104471505B (en) * | 2012-07-11 | 2018-06-29 | 伟创力有限责任公司 | Direct action type solenoid actuator |
DE102013220740A1 (en) * | 2013-10-14 | 2015-04-16 | Continental Automotive Gmbh | Valve |
JP6340938B2 (en) * | 2014-06-17 | 2018-06-13 | 日立金属株式会社 | Manufacturing method of cable with resin molding |
US9970792B2 (en) * | 2014-08-11 | 2018-05-15 | Continental Automotive Systems, Inc. | Stepper motor assembly having opposite shafts |
PL3379700T3 (en) * | 2017-03-21 | 2020-07-13 | Fischer & Kaufmann Gmbh & Co. Kg | Housing and method for producing same |
EP3419146B1 (en) | 2017-04-11 | 2022-08-10 | Guilin Zhishen Information Technology Co., Ltd. | Motor housing |
CN106803696B (en) * | 2017-04-11 | 2018-06-05 | 桂林智神信息技术有限公司 | A kind of motor housing with hollow shaft |
US10215105B1 (en) * | 2017-10-12 | 2019-02-26 | Continental Automotive Systems, Inc. | Integrated VDA housing with anti-rotation feature |
US11174799B2 (en) * | 2018-03-05 | 2021-11-16 | Vitesco Technologies USA, LLC | Integrated VDA housing with anti-rotation feature |
US10711710B2 (en) * | 2018-05-08 | 2020-07-14 | Continental Powertrain USA, LLC | Reduced material spigot design for integrated VDA adapter housing with as-cast anti-rotation feature |
JP7244248B2 (en) * | 2018-10-09 | 2023-03-22 | 日本電産サンキョー株式会社 | Actuator fixing structure |
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-
2011
- 2011-04-05 KR KR1020127030641A patent/KR101812715B1/en active IP Right Grant
- 2011-04-05 US US13/642,677 patent/US9144936B2/en not_active Expired - Fee Related
- 2011-04-05 EP EP11714209.1A patent/EP2561600B1/en not_active Not-in-force
- 2011-04-05 CN CN201180020355.1A patent/CN102844967B/en not_active Expired - Fee Related
- 2011-04-05 AU AU2011243111A patent/AU2011243111B2/en not_active Ceased
- 2011-04-05 MX MX2012012249A patent/MX2012012249A/en active IP Right Grant
- 2011-04-05 JP JP2013506166A patent/JP5575329B2/en not_active Expired - Fee Related
- 2011-04-05 WO PCT/US2011/031270 patent/WO2011133320A2/en active Application Filing
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2014
- 2014-10-15 US US14/514,528 patent/US20150083322A1/en not_active Abandoned
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JP2002027688A (en) * | 2000-07-10 | 2002-01-25 | Tsurumi Mfg Co Ltd | Structure for stopping whirl of stator core in submerged motor |
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Also Published As
Publication number | Publication date |
---|---|
JP5575329B2 (en) | 2014-08-20 |
WO2011133320A2 (en) | 2011-10-27 |
US9144936B2 (en) | 2015-09-29 |
EP2561600A2 (en) | 2013-02-27 |
JP2013526250A (en) | 2013-06-20 |
MX2012012249A (en) | 2012-11-23 |
CN102844967B (en) | 2016-08-17 |
KR20130100902A (en) | 2013-09-12 |
CN102844967A (en) | 2012-12-26 |
AU2011243111B2 (en) | 2014-03-20 |
AU2011243111A1 (en) | 2012-10-04 |
EP2561600B1 (en) | 2017-06-28 |
US20130104842A1 (en) | 2013-05-02 |
WO2011133320A3 (en) | 2012-08-09 |
KR101812715B1 (en) | 2017-12-27 |
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