WO2000008340A1 - Unitary coil and valve assembly - Google Patents

Unitary coil and valve assembly Download PDF

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Publication number
WO2000008340A1
WO2000008340A1 PCT/US1999/001858 US9901858W WO0008340A1 WO 2000008340 A1 WO2000008340 A1 WO 2000008340A1 US 9901858 W US9901858 W US 9901858W WO 0008340 A1 WO0008340 A1 WO 0008340A1
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WO
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Patent type
Prior art keywords
bobbin
body
spool
port
includes
Prior art date
Application number
PCT/US1999/001858
Other languages
French (fr)
Inventor
Timothy L. Johnson
Christopher C. Knoll
Original Assignee
Snap-Tite Technologies, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/06Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with two or more servomotors
    • F15B13/08Assemblies of units, each for the control of a single servomotor only
    • F15B13/0803Modular units
    • F15B13/0821Attachment or sealing of modular units to each other
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/04Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with a single servomotor
    • F15B13/0401Valve members; Fluid interconnections therefor
    • F15B13/0402Valve members; Fluid interconnections therefor for linearly sliding valves, e.g. spool valves
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/04Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with a single servomotor
    • F15B13/0401Valve members; Fluid interconnections therefor
    • F15B13/0405Valve members; Fluid interconnections therefor for seat valves, i.e. poppet valves
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/04Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with a single servomotor
    • F15B13/044Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with a single servomotor operated by electrically-controlled means, e.g. solenoids, torque-motors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/06Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with two or more servomotors
    • F15B13/08Assemblies of units, each for the control of a single servomotor only
    • F15B13/0803Modular units
    • F15B13/0807Manifolds
    • F15B13/0817Multiblock manifolds
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/06Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with two or more servomotors
    • F15B13/08Assemblies of units, each for the control of a single servomotor only
    • F15B13/0803Modular units
    • F15B13/0828Modular units characterised by sealing means of the modular units
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/06Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with two or more servomotors
    • F15B13/08Assemblies of units, each for the control of a single servomotor only
    • F15B13/0803Modular units
    • F15B13/0832Modular valves
    • F15B13/0835Cartridge type valves
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVO-MOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B13/00Details of servomotor systems ; Valves for servomotor systems
    • F15B13/02Fluid distribution or supply devices characterised by their adaptation to the control of servomotors
    • F15B13/06Fluid distribution or supply devices characterised by their adaptation to the control of servomotors for use with two or more servomotors
    • F15B13/08Assemblies of units, each for the control of a single servomotor only
    • F15B13/0803Modular units
    • F15B13/0846Electrical details
    • F15B13/0857Electrical connecting means, e.g. plugs, sockets
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16KVALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K31/00Actuating devices; Operating means; Releasing devices
    • F16K31/02Actuating devices; Operating means; Releasing devices electric; magnetic
    • F16K31/06Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
    • F16K31/0644One-way valve
    • F16K31/0668Sliding valves

Abstract

A solenoid valve comprises a unitary coil and valve assembly. The unitary coil and valve assembly is affixed to the body (1) by a clip (6) which extends from the exterior of the body (1) through a portion of the body (1) and into a portion of a circumferential groove in the unitary coil and valve assembly. The body (1) also includes a first set of electrical contacts (31). The unitary coil and valve assembly also includes a second set of electrical contacts (32) which mate with the first set of electrical contacts (31) when the unitary coil and valve assembly is affixed to the body (1). The unitary coil and valve assembly includes a spool (8) which is partially overmolded with rubber. The overmolded spool (8) seats against a bobbin having passageways therethrough so as to permit communication between ports in the body (1). The overmolded spool (8) and associated plunger (10) are movable between first and second positions.

Description

UNITARY COIL AND VALVE ASSEMBLY Field of the Invention The instant invention relates to solenoid valves which are quickly and inexpensively removed and replaced. A unitary coil and valve assembly is affixed to a body by means of a clip. Electrical power is supplied to the coil by a first set of contacts which reside in the body in combination with a second set of contacts which are part of the unitary coil and valve assembly. If, for any reason, the unitary coil and valve assembly requires maintenance, repair or disposal it may be quickly and inexpensively removed without determinating any wires or leads and without disconnecting any pipes, tubes or conduits from any of the ports in the body.

Background of the Invention United States Patent No. 5,180,318 to Moller et al. discloses connector modules which are interconnected longitudinally and include neutral, signal and grounded conductors. The signal conductor is installed using a screwdriver as is illustrated in Fig. 4 of the '318 patent.

United States Patent No. 5,178,548 to Fortmann et al. discloses contact pins which mate with receptacles. Rotor bodies having conductive and ductile properties serve as contact rings and electrical conductors. United States Patent No. 5,581,222 to Pinaud discloses a rapid assembly solenoid valve having a groove which is secured by a wire spring clip to the housing of the valve. The wire spring clip is disclosed and claimed as being pivotally mounted to the housing.

United States Patent No. 4,805,870 to Mertz discloses a spring clip secured to the housing by means of spot welding or the like. United States

Patent No. 5,158,475 to Tyler discloses a spring clip which resiliently grips the bare wire end of a conductor that is inserted into a connector.

United States Patent No. 4,880,033 to Neff discloses a poppet valve wherein the spool valve includes an annular molded poppet valve member 50 which during assembly must be forced over its seating surfaces.

None of the related art discloses or suggests a solenoid valve having a unitary coil and valve assembly which is affixed to a body by means of a clip. Nor does the related art suggest or disclose electrical power supplied to a coil by a first set of contacts which reside in the body in combination with a second set of contacts which are part of the unitary coil and valve assembly.

Summary of the Invention A solenoid valve comprising a unitary coil and valve assembly and a body is disclosed. The unitary coil and valve assembly include the first bobbin and a second bobbin. The second bobbin is ultrasonically welded to the first bobbin forming a bobbin assembly. A coil is wound around the second bobbin. A balanced spool having first and second positions is provided. The balanced spool includes an elongated stem portion which engages a plunger. The plunger also has first and second positions.

The balanced spool is partially overmolded with rubber. The partially overmolded portion of the balanced spool engages the bobbin assembly. A washer and a stop are also overmolded to the second bobbin.

The balanced spool includes a bore. A spring partially resides in the bore of the balanced spool and urges the balanced spool toward its second position. The first bobbin includes first and second exterior slots. The body includes first and second bores for receiving the clip. A clip extends from the exterior of the body and through a portion of the body and into the first and second slots of the first bobbin affixing the first and second bobbins (and, hence, the unitary coil and valve assembly) to the body.

The body includes a first port, a second port and a third port. The first and second ports reside in a first horizontal plane and the third port resides in a second horizontal plane. The second bobbin includes a first passageway which communicates with the first port of the body. The first bobbin includes a second passageway which communicates with the second port of the body. The first bobbin includes a third passageway which communicates with the third port of the body. The first and second ports of the body communicate when the balanced spool and the plunger are in their first respective positions.

The second and third ports of the body communicate when the balanced spool and the plunger are in their respective second positions. The first bobbin and the second bobbin comprise the bobbin assembly as the first and second bobbins are ultrasonically welded together. Therefore, the first passageway in the second bobbin, the second passageway in the first bobbin, and the third passageway in the first bobbin are sometimes described later herein as the first, second and third passageways of the bobbin assembly.

The body includes a first set of electrical contacts. The unitary coil and valve assembly includes a second set of electrical contacts. The first set of electrical contacts engage the second set of electrical contacts when the unitary coil and valve assembly is affixed to the body. The second set of electrical contacts are wired to the coil. The first set of electrical contacts are wired to a power source. A plate is ultrasonically welded to the second body. An enclosure is ultrasonically welded to the plate and to the second bobbin. Alternatively, instead of employing ultrasonic welding those skilled in the art may weld by other methods or may use adhesive.

It is an object of the invention to provide a unitary coil and valve assembly which can be quickly and easily removed from the body without having to determinate any electrical wires or pipeline connections. It is a further object of the present invention to provide a unitary coil and valve assembly which is secured to the body by a clip.

It is a further object of the present invention to provide a unitary coil and valve assembly which is affixed to the body by a clip. It is a further object of the present invention to provide a solenoid valve having a unitary coil and valve assembly, a first set of electrical contacts and a second set of electrical contacts.

It is a further object of the present invention to provide a solenoid valve comprising a unitary coil and valve assembly which includes a spool which moves in conjunction with a plunger. The spool is a balanced spool and includes an overmolded portion. The overmolded portion of the body engages various seating surfaces of the bobbin thus allowing flow through the bobbin and hence through the body in the desired fashion. It is a further object of the present invention to provide a solenoid valve which includes a first and second bobbin which are ultrasonically welded together.

It is a further object of the present invention to provide a washer and a stop which are overmolded to a second bobbin. It is a further object of the present invention to provide a solenoid valve which includes a bobbin which is ultrasonically welded to a plate.

It is a further object of the present invention to provide an enclosure which encloses the housing and second bobbin.

It is a further object of the present invention to provide a manual operator for moving the plunger and the spool from their second positions to their respective first positions.

It is a further object of the present invention to provide a solenoid valve which includes a unitary coil and valve assembly which controls the flow of gas or other fluid between any two of the three ports of the body. It is a further object of the present invention to provide a bobbin assembly comprised of the first bobbin and the second bobbin.

The objects of the invention will be better understood when taken in conjunction with the brief description of the drawings and the detailed description of the invention which follow below.

Brief Description of the Drawings Fig. 1 is a side view of the solenoid valve illustrating the body and the first port of the body as well as the unitary coil and valve assembly shown partially in cross-section.

Fig. 2 is a front view of the solenoid valve illustrating the body and the third port of the body as well as the unitary coil and valve assembly shown partially in cross-section.

Fig. 3 is a cross-sectional view of the solenoid valve taken along the lines 3-3 of Fig. 1 illustrating the body and the first and second ports of the body as well as the unitary coil and valve assembly. Fig. 3 also illustrates the unitary coil and valve assembly ultrasonically welded to a plate. Fig. 3 also illustrates an ultrasonically welded two-piece bobbin, an overmolded spool, a plunger, a coil and a spring. Fig. 3 illustrates the spool and the plunger in their second positions. When the spool and the plunger are in their second positions the second port in the body communicates with the third port in the body. Fig. 3 illustrates the condition that exists when the coil is deenergized. Fig. 3 A is an enlarged view of a portion of Fig. 3 illustrating the spool and the bobbins. The spool is in its second position in Fig. 3A as shown. Fig. 4 is a cross-sectional view of the solenoid valve similar to the view illustrated in Fig. 3 except the plunger and spool are illustrated in their respective first positions. Fig. 4 illustrates the first port in the body communicating with the second port in the body. Fig. 4 illustrates the condition that exists when the coil is energized. Fig. 4A is an enlarged view of a portion of Fig. 4 illustrating the spool and the bobbins. The spool is in its first position in Fig. 4A as shown.

Fig. 5 is a cross-sectional view of the unitary coil and valve assembly taken along the lines 3-3 of Fig. 1. Fig. 6 is a cross-sectional front view of the body. Fig. 7 is a sectional view taken along the lines 7-7 of Fig. 2 illustrating the first port as well as one of the electrical contacts of the unitary coil and valve assembly and one of the electrical contacts of the body. Fig. 8 is a view taken along the lines 8-8 of Fig. 2 illustrating the body and second port in cross-section as well as one of the electrical contacts of the unitary coil and valve assembly (illustrated in a fragmentary cross-section view) and one of the electrical contacts of the body.

Fig. 9 is a cross-sectional view taken along the lines 9-9 of Fig. 2 illustrating the third port with the plunger and the spool in their respective second positions.

Fig. 10 is an isometric view of a portion of the unitary coil and valve assembly.

Fig. 11 is a diagram of process steps in assembling the unitary coil and valve assembly.

Detailed Description of the Invention Fig. 1 is a side view of the solenoid valve illustrating the body 1 and the first port 17 of the body as well as the unitary coil and valve assembly shown partially in cross-section. The unitary coil and valve assembly is best illustrated in Fig. 5. Fig. 1 further illustrates the first passageway 28 in the first port 17 of the body 1. Clip 6 is partially shown exterior to the body 1. Clip 6 is a spring loaded clip which grips the slots 41 and 41' of the first bobbin 3. See, Fig. 5 which illustrates the slots 41 and 41'. The spring loading of the clip 6 keeps the clip in engagement with the slots 41 and 41' and the first and second bores 46, 47 in the body 1. See, Fig 6. Alternatively, or in addition, clip 6 may have serration 70 to insure that it stays in place securing the bobbin assembly (comprising the first bobbin 3 and second bobbin 4) in place with respect to the body. The strap 13 which houses the electrical coil is shown in Fig. 1 as well.

An electrical lead wire 37 is illustrated leading from the first electrical contact 31 to the coil 5 which is inside strap 13. Sometimes first electrical contact 31 is referred to herein as the first coil contact. Contact 31 is clipped onto stud 31 ' and mates with third electrical contact 34. Contact 31 is part of the unitary coil and valve assembly 2 and moves therewith when the unitary coil and valve assembly is separated from the body 1. Contact 34 is affixed to the body 1.

Reference numeral 23 illustrates the ultrasonic welding of plate 12 and enclosure 45. Fig. 10 illustrates the energy director 23 ' and its generally triangular shape (considered in cross-section). Fig. 10 also illustrates energy director 44' on second bobbin 4 and its shape. When ultrasonically welded, the energy directors effectively melt and adhere the enclosure 45 to the second bobbin as indicated by reference numeral 44 and adhere the enclosure 45 to the plate 12 as indicated by reference numeral 23. Enclosure 45 is ultrasonically welded to the plate 12 and to the second bobbin 4. Energy director 44' and energy director 23 ' focus the energy transmitted during the ultrasonic welding process.

The enclosure 45, plate 12, and body 1 are nylon. Contacts 31 and 34 are beryllium copper and housing 13 and clip 6 are steel. The energy directors

44' and 23' are also nylon.

Fig. 2 is a front view of the solenoid valve illustrating the body and the unitary coil and valve assembly partially in cross-section. Third port 27 and the third passageway 30 of the body 1 are illustrated. Second electrical contact 32, sometimes referred to as the second coil contact, is clipped onto stud 32'. Body mounting bores 40 and 40' enable attachment of the body to the user's structure. Reference numeral 37' is the second electrical lead wire to the coil from the second coil contact 32. Contact 32 is affixed to the unitary coil and valve assembly and moves therewith.

Figs. 3 and 3 A illustrate the second position of spool 8 when the coil is deenergized.

Fig. 3 is a cross-sectional view of the solenoid valve taken along the lines 3-3 of Fig. 1 illustrating the body 1 and the first port 17 in body 1 and the second port 18 in body 1. First nylon bobbin 3 is ultrasonically welded to second nylon bobbin 4 and together comprise the bobbin assembly. Coil 5 is made of insulated copper wire and is wound around second bobbin 4. An overmolded spool 8 includes a portion 9 which is overmolded and an elongated portion 11 which is not overmolded. The spool is aluminum or nylon and the overmolded material of the spool is a rubber. Vent 43 allows for the escape of unwanted air or other gasses which may occur during assembly of the unitary coil and valve assembly 2. Vent 43 allows air above the spool, entrapped above third protrusion 60, to communicate with air below the spool, entrapped below second protrusion 56. This communication allows the pressure of the entrapped air to be applied equally in opposite directions, and the forces on the spool are balanced. Clip 6 is shown in cross-section securing the bobbin 3 and hence the entire unitary coil and valve assembly 2 in place with respect to the body 1. First bobbin 3 is made of nylon and clip 6 is made of steel.

Removal of the unitary coil and valve assembly from the body is accomplished by removing clip 6 from the body 1 (See, Figs. 1, 3 and 10) and simply pulling or separating the unitary coil and valve assembly 2 away from the body. Referring to Fig. 3, stop 15 and washer 14 are overmolded to second bobbin 4. Stop 15 is made of 430 stainless steel and washer 14 is made of carbon steel. Reference numeral 35 indicates that the second bobbin 4 is ultrasonically welded to nylon plate 12. Fig. 3 illustrates the plunger 10 and the spool 8 in their respective second positions. In their second positions, flow is permitted between the second port 18 and third port 27 of the body.

Fig. 3 A is an enlarged view of a portion of Fig. 3 illustrating the spool and the bobbins. Referring to Fig. 3A, seals 24 and 25 seal the first passageway 49 in the bobbin assembly. The bobbin assembly is a two piece assembly comprised of first bobbin 3 and second bobbin 4 ultrasonically welded together. Reference numeral 57 indicates the ultrasonic welding of first bobbin 3 to second bobbin 4. Seals 25 and 26 seal the second passageway 50 of the bobbin assembly. See, Fig. 9, a cross-sectional view taken along the lines 9-9 of Fig. 2 illustrating the third port 27, the passageway

30 in the body and the third passageway 51 in the bobbin assembly. Fig. 9 illustrates seals 26 and 48 sealing the third passageway. Seals 24, 25, 26 and 48 are elastomeric 0-ring seals.

Referring to Fig. 3, the coil 5 is not energized and the spool 8 and plunger 10 are in their respective second positions under the urging of spring 7 which urges the spool 8 and the plunger 10 away from the first bobbin 3. Bobbin 3 has a bore 16 and spring 7 is housed partially in the bore 16. See, Fig. 3 A. Annulus 52 is generally bounded by the overmolded portion 9 of spool 8 and the inside bore 54 of bobbin 3. Annulus 52 facilitates communication of fluid flow between the second passageway 50 in the bobbin assembly with third passageway 51 in the bobbin assembly. See, Fig. 9 to view the third passageway 51 in the bobbin assembly.

Figs. 4 and 4A illustrate the first position of the spool when the coil is energized. Fig. 4 is a cross-sectional view of the solenoid valve similar to the view illustrated in Fig. 3 except the plunger 10 and spool 8 are illustrated in their respective first positions. Fig. 4 illustrates the first port 17 in body 1 communicating with the second port 18 in the body 1. Figs. 3 and 4 both illustrate a washer 14 overmolded to second bobbin 4. Operator 21 is a polyethylene manual operator which allows for manual operation of the solenoid valve if desired. Seal 20 seals the operator against the interior bore of the second bobbin. Operator 21 is restrained in its downward movement toward the body by the plunger 10. Enclosure 45 captures and retains the operator from exiting the assembly. Figs. 3 and 4 illustrate the unitary coil and valve assembly flush against the body 1. Reference numeral 22 indicates the engagement of the unitary coil and valve assembly with the body 1. Fig. 4A illustrates an annulus between the spool 8 and the second bobbin 4. Reference numeral 53 indicates the annulus which permits flow between the first port 17 and the second port 18.

Figs. 3 and 3 A depict the valving action of the spool with respect to the bobbin assembly when the coil 5 is deenergized. In particular, protrusion 55 engages shoulder 59 of the bobbin assembly to prohibit flow to the second passageway 50 of the bobbin assembly. Reference numeral 61 indicates the flow path from the second passageway 50 of the bobbin assembly to the third passageway 51 of the bobbin assembly. See, Fig. 9. Figs. 4 and 4A depict the valving action of the spool with respect to the bobbin assembly when the coil 5 is energized. In particular, protrusion 55 engages shoulder 58 of the bobbin assembly to prohibit flow to the third passageway 51 of the bobbin assembly.

Reference numeral 62 represents the flow path from the first passageway 49 to the second passageway 50 of the bobbin assembly. Figs. 3 A and 4A illustrate seals 26 and 48 for sealing the third passageway 51 in the bobbin assembly. Referring to Figs. 3 A and 4A, the overmolded portion 9 of spool 8 includes a first protrusion 55, a second protrusion 56 and a third protrusion 60.

Spool 8, in its second position as illustrated in Fig. 3A, may have pressure applied to annulus 53, first protrusion 55 and third protrusion 60. Protrusions 55 and 60 have approximately the same pressurized cross-sectional area and are exposed to any fluid pressure within the annulus 53 and as a result the spool is substantially pressure balanced. Similarly, spool 8, in its first position as illustrated in Fig. 4A, may have pressure applied to annulus 52, first protrusion 55 and third protrusion 56. Protrusion 55 and 56 have approximately the same pressurized cross-sectional area exposed to any fluid pressure within annulus 52 and, as a result, the spool is substantially pressure balanced.

The overmolded portion 9 of the spool 8 provides a seal against fluid pressure. For instance, referring to Figs. 3A and 4A third protrusion 60 and second protrusion 56 prevent the escape of fluid flow into unwanted areas past protrusion 60 and 56 and above or below the overmolded portions of the spool.

Fig. 5 illustrates the unitary coil and valve assembly 2. Reference numerals 41 and 41' represent the first and second slots respectively in the first bobbin 3. These slots 41 and 41' in combination with the clip 6 retain the unitary coil and valve assembly 2 in position with respect to the body 1.

Fig. 6 is a cross-sectional view of the body 1. Reference numerals 46 and 47 are the first and second bores in the body 1 for receiving the clip 6.

Fig. 6 also illustrates the first mounting hole 40 and second mounting hole 40' for affixing the body 1 of the solenoid valve to the structure of the user. Fig 6 also shows the first passageway 28 in the first port 17 and the second passageway 29 in the second port 18.

Fig. 7 is a sectional view taken along the line 7-7 of Fig. 2 illustrating the first port 17 as well as one of the electrical contacts 31 of the unitary coil and valve assembly and one of the electrical contacts 34 of the body 1. Body

1 includes stud 34' to which electrical contact 34 is clipped onto and held in place by the friction of the contact against the stud. An 0-ring 36 seals the plate 12 with respect to the body 1. When the unitary coil and valve assembly 2 is affixed to the body 1 the contacts 34 and 31 mutually engage producing a pathway for electrical current to flow. Reference numeral 38 indicates a power lead from a power source to the contact 34.

Fig. 8 is a view taken along the lines 8-8 of Fig. 2 illustrating the body and second port 18 in cross-section as well as the fourth electrical contact 39, affixed to stud 39' of the body. The second electrical contact 32 is shown affixed to the stud 32' in the unitary coil and valve assembly. 0-ring 36' is illustrated for sealing the contacts 32 and 39 when the unitary coil and valve assembly mates with the body 1. Contacts 32 and 39 conduct electric current when the unitary coil and valve assembly mates with the body as do contacts

31 and 34. Of course, another device controls the application of power to the coil 5.

Fig. 9 illustrates a cross-sectional view taken along the lines 9-9 of Fig. 2 illustrating the third port 27, the third passageway 30 in the third port 27, and the third passageway 51 in the bobbin assembly. Fig. 9 illustrates the communication between the second and third ports of the body when the plunger and spool are in their respective second positions.

Fig. 10 is an isometric view of the unitary coil and valve assembly 2. Fig. 10 illustrates an isometric view of a portion of the unitary coil and valve assembly. Passageways 30 and 49 are illustrated in the bobbin assembly and the energy directors 23' and 44' are best seen in this view.

A novel process for assembling the unitary coil and valve assembly is disclosed herein. Referring to Fig. 3, the spool and its elongated portion 11 is a one piece assembly. The one piece spool assembly minimizes the tolerance buildup which occurs in traditional solenoid valve constructions where a push pin is used in combination with a spool. The engagement of the spool with the plunger as illustrated in Fig. 3 insures that the plunger and spool can travel far enough from their second positions as shown in Fig. 3 to their first positions as shown in Fig. 4 without the plunger interfering with (i.e. engaging) stop 15. Stop 15 is overmolded to bobbin 4 and the tolerances of the stop relative to the bobbin are thus well controlled.

The steps of assembling the unitary coil and valve assembly include: overmolding a stop 15 to a second bobbin 4; overmolding rubber onto the spool; installing the spool in said second bobbin and said stop; installing a spring in the bore of the spool; welding a first bobbin 3 to the second bobbin 4 to form a bobbin assembly, welding the bobbin assembly to the plate; and affixing the bobbin assembly to the body. Fig. 11 illustrates the process steps. The foregoing description of the invention is set forth by way of example only and is not intended to limit the scope and coverage of the claims which follow hereinbelow. Those skilled in the art will readily recognize that several modifications and changes may be made to the foregoing invention without departing from the spirit and the scope of the claims which follow below.

Claims

What is claimed is:
1. A solenoid valve comprising: a body; said body including a first port, a second port and a third port; a first bobbin; a second bobbin; said first and said second bobbins being affixed together and forming a bobbin assembly; a spool; a plunger; a coil; said bobbin assembly includes a first passageway, a second passageway, and a third passageway communicating with said first port in said body, said second port in said body, and said third port in said body, respectively; and, said spool includes valve means to control communication between said ports.
2. A solenoid valve as claimed in claim 1 further comprising means for retaining said bobbin assembly in said body.
3. A solenoid valve as claimed in claim 2 further comprising a plate; and, said bobbin assembly being affixed to said plate.
4. A solenoid valve comprising a body; a unitary coil and valve assembly; a clip; and said clip affixing said unitary coil and valve assembly to said body.
5. A solenoid valve comprising a body; a unitary coil and valve assembly; a first contact affixed to said body; a second contact affixed to said unitary coil and valve assembly; and, said first and second contacts engage each other when said unitary coil and valve assembly engages said body.
6. A solenoid valve as claimed in claim 4 wherein said unitary coil and valve assembly includes a spool partially overmolded with rubber.
7. A solenoid valve as claimed in claim 5 wherein said unitary coil and valve assembly includes a spool partially overmolded with rubber.
8. A solenoid valve as claimed in claim 4 wherein said unitary coil and valve assembly includes a stop, a washer and a bobbin; and, said stop and washer are overmolded to said bobbin.
9. A solenoid valve as claimed in claim 5 wherein said unitary coil and valve assembly includes a stop, a washer and a bobbin; and, said stop and washer are overmolded to said bobbin.
10. A solenoid valve as claimed in claim 6 wherein said spool includes an elongated stem portion.
11. A solenoid valve as claimed in claim 7 wherein said spool includes an elongated stem portion.
12. A solenoid valve comprising: a body; said body includes a first port, a second port, and a third port; a unitary coil and valve assembly affixed to said body; said unitary coil and valve assembly includes a bobbin and a balanced spool; said bobbin includes first, second and third passageways communicating with said first, second and third ports; said first and second port lying in a first horizontal plane and said third port lying in a second horizontal plane; said balanced spool having a first position and a second position; said first and second ports communicating when said balanced spool is in said first position; and, said second and third ports communicating when said balanced spool is in said second position.
13. A solenoid valve as claimed in claim 10 further comprising a plunger; and, wherein said elongated stem portion of said spool engages said plunger.
14. A solenoid valve as claimed in claim 11 further comprising a plunger; and, wherein said elongated stem portion of said spool engages said plunger.
15. A solenoid valve comprising: a unitary coil and valve assembly; a body; said body having an exterior; said unitary coil and valve assembly includes a first bobbin and a second bobbin; said second bobbin being ultrasonically welded to said first bobbin; a coil; said coil being wound around said second bobbin; a plunger; said plunger having first and second positions; a stop; a washer; said washer and said stop being overmolded to said second bobbin; a balanced spool; said balanced spool having first and second positions; said balanced spool includes an elongated stem portion engaging said plunger; a spring; said balanced spool being partially overmolded with rubber; said partially overmolded portion of said balanced spool engaging said first bobbin and said second bobbin; a spring; said balanced spool includes a bore; said spring partially resides in said bore of said balanced spool and urges said balanced spool toward its second position; said first bobbin includes a first slot and a second slot; said body includes a first and second bore; a clip; said clip extends from said exterior of said body and through a portion of said body and into said first and second slots of said first bobbin affixing said first and second bobbins to said body; said body includes a first port, a second port, and a third port; said first and second ports reside in a first horizontal plane and said third port resides in a second horizontal plane; said second bobbin includes a first passageway which communicates with said first port of said body; said first bobbin includes a second passageway which communicates with said second port of said body; said first bobbin includes a third passageway which communicates with said third port of said body; said first and second ports of said body communicate when said balanced spool and said plunger are in their respective first positions; said second and third ports of said body communicate when said balanced spool and said plunger are in their respective second positions; said body includes a first set of electrical contacts; said unitary coil and valve assembly includes a second set of electrical contacts; said first set of electrical contacts engage said second electrical contacts when said unitary coil and valve assembly is affixed to said body; a plate ultrasonically welded to said second bobbin; and, an enclosure ultrasonically welded to said plate and to said second bobbin.
16. A solenoid as claimed in claim 15 further comprising means for sealing said first port, said second port and said third port.
17. A solenoid as claimed in claim 16 further comprising a manual operator for moving said plunger and said balanced spool from their respective second positions to their respective first positions.
18. A process for assembling a solenoid and valve assembly which includes a first and second bobbin, a stop overmolded to said second bobbin, an overmolded spool having a bore therein, a spring and a body comprising the steps of: overmolding a stop to the second bobbin; overmolding rubber to the spool; installing the overmolded spool in said second bobbin and said stop; installing a spring in said bore of said spool; affixing said first bobbin and said second bobbin together forming a bobbin assembly; and affixing said bobbin assembly to said body.
PCT/US1999/001858 1998-08-03 1999-02-04 Unitary coil and valve assembly WO2000008340A1 (en)

Priority Applications (2)

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US12817998 true 1998-08-03 1998-08-03
US09/128,179 1998-08-03

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AU2565999A AU2565999A (en) 1998-08-03 1999-02-04 Unitary coil and valve assembly

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007118674A2 (en) * 2006-04-12 2007-10-25 Miro Gudzulic On-off valve
JP2013190028A (en) * 2012-03-14 2013-09-26 Nachi Fujikoshi Corp Solenoid valve

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3202182A (en) * 1961-10-16 1965-08-24 Jacobs Mfg Co Balanced poppet valve
US4529006A (en) * 1981-06-10 1985-07-16 Bochumer Eisehutte Heitzmann GmbH & Co. KG Electrohydraulic three-port, two position valve
US4552179A (en) * 1983-08-25 1985-11-12 Ckd Corporation Miniature solenoid valve
US4711265A (en) * 1987-03-16 1987-12-08 General Motors Corporation Spring and washer device
US4915134A (en) * 1989-07-27 1990-04-10 Humphrey Products Company Three-way poppet valve with hollow stem
US5513673A (en) * 1994-05-23 1996-05-07 Lectron Products, Inc. Electrically modulated pressure regulator valve with variable force solenoid

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3202182A (en) * 1961-10-16 1965-08-24 Jacobs Mfg Co Balanced poppet valve
US4529006A (en) * 1981-06-10 1985-07-16 Bochumer Eisehutte Heitzmann GmbH & Co. KG Electrohydraulic three-port, two position valve
US4552179A (en) * 1983-08-25 1985-11-12 Ckd Corporation Miniature solenoid valve
US4711265A (en) * 1987-03-16 1987-12-08 General Motors Corporation Spring and washer device
US4915134A (en) * 1989-07-27 1990-04-10 Humphrey Products Company Three-way poppet valve with hollow stem
US5513673A (en) * 1994-05-23 1996-05-07 Lectron Products, Inc. Electrically modulated pressure regulator valve with variable force solenoid

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007118674A2 (en) * 2006-04-12 2007-10-25 Miro Gudzulic On-off valve
WO2007118674A3 (en) * 2006-04-12 2007-12-13 Miro Gudzulic On-off valve
JP2013190028A (en) * 2012-03-14 2013-09-26 Nachi Fujikoshi Corp Solenoid valve

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