WO2005030528A2

WO2005030528A2 - Solenoid coil having interior terminals and method for fixing

Info

Publication number: WO2005030528A2
Application number: PCT/US2004/031077
Authority: WO
Inventors: Dennis Dukaric; Douglas Lewin
Original assignee: Kelsey-Hayes Company
Priority date: 2003-09-22
Filing date: 2004-09-22
Publication date: 2005-04-07
Also published as: WO2005030528A3

Abstract

A solenoid coil (30) includes an open ended axial bore (42) formed therethrough and at least one terminal support (40) extending from one end thereof in a direction parallel to the axial bore (42) and having a portion extending over an end of the bobbin bore. The tenninal support (40) carries a terminal pin (44) and is supported by a tool extending through the coil bore while the coil is assembled onto a printed circuit board.

Description

SOLENOID COIL HAVING INTERIOR TERMINALS AND METHOD FOR FIXING

Background of Invention

[0001] This invention relates in general to solenoid valves for Electronically

Controlled Brake Systems and in particular to a coil for a solenoid valve having electrical terminals extending in an axial direction from an interior portion thereof.

[0002] Electronically Controlled Brake Systems (ECBS), such as, for example, Anti-lock Brake Systems (ABS), Traction Control Systems (TC) and Vehicle Stability Control Systems (VSC) are often included as standard or optional equipment on new vehicles. When actuated, the ECBS is operative to control the operation of some or all of the vehicle wheel brakes. A typical ECBS includes a plurality of solenoid valves mounted within a control valve body and connected to the vehicle hydraulic brake system. Additionally, a separate hydraulic source, such as a motor driven pump, is usually included in the ECBS control valve body for supplying pressurized hydraulic pressure to the controlled wheels during an ECBS cycle. An ECBS further includes an electronic control module which is electrically connected to the pump motor, a plurality of solenoid coils associated with the solenoid valves, and wheel speed sensors for monitoring the speed and deceleration of the controlled wheels. The electronic control module, which typically includes a microprocessor with a stored algorithm for controlling the ECBS, is usually mounted upon the control valve body. The assembled valve body, motor and control module forming a compact unit which is often referred to as an ECBS control valve. The ECBS may also include acceleration and yaw sensors for detecting motions of the vehicle.

[0003] During vehicle operation, the microprocessor within the ECBS control module continuously receives speed signals from the wheel speed sensors and, if present, the vehicle motion sensors. The control module microprocessor also monitors the sensor signals for potential activation conditions, such as wheel lock up for an ABS. When a potential problem is detected, the control module microprocessor is operative to actuate the pump motor, and to selectively operate the solenoid valves in the control valve to cyclically relieve and reapply hydraulic pressure to the controlled wheel brakes. The hydraulic pressure applied to the controlled brakes is adjusted by the operation of the solenoid valves to correct the potential problem.

[0004] Referring now to Fig. 1, there is shown a partial sectional view of a portion of a typical known ECBS control valve 10. The control valve 10 includes a plurality of solenoid valves 11 (one shown) mounted in a valve body 12. Each of the solenoid valves 11 has a valve sleeve 13 which extends upwardly from the top surface of the valve body 12. Each valve sleeve 13 encloses an axially movable solenoid armature (not shown) which carries a valve ball on one end. As will be explained below, the valve sleeves 13 prevent loss of hydraulic fluid from the control valve 10 during servicing of the electronic control module.

[0005] Each valve 11 also includes a solenoid coil 15. As illustrated in Fig. 1, the coil 15 includes a winding 16 comprising a plurality of turns of fine wire wound upon a bobbin 17 having an axial center bore formed therethrough. The ends of the winding wire are wound onto a pair of rigid coil leads, or terminals, 18 which extend in an upward direction from the coil 15. Each terminal 18 is carried by a supporting post 19 formed upon and extending axially from an upper end flange of the bobbin 17. As illustrated in Fig. 1, the posts 19 are located midway between bobbin center bore and the edge of the bobbin flange. Thus, the posts 19 and terminals 18 are supported from beneath by the coil winding 16. An annular flux ring 20 is disposed between the coil 15 and the valve 11. A cylindrical flux casing 21 encloses the coil 15. A pair of lead apertures 22 are formed through the top surface of the casing 21. The coil leads 18 extend through both the casing lead apertures 22 and a second pair of apertures 23 formed through a Printed Circuit Board (PCB) 24. The PCB 24 has electrical traces 25 formed upon its upper surface. The coil leads 18 are electrically connected to the traces 25 by solder connections 26. Electricity is supplied through the electrical traces 25 and coil leads 18 to the coil 15. The coil 15 generates a magnetic flux field which actuates the solenoid valve 11. The flux ring 20 and flux casing 21 cooperate to provide a low reluctance return path for the magnetic flux field.

[0006] Typically, the PCB 24 carries a microprocessor and other electronic components (not shown) for controlling the ECBS. As shown in Fig. 1, a removable cover 27 encloses the solenoid coils 15 and the PCB 24. The PCB 24 is usually attached to the cover 27 to form a compact integrated electronic control module 28. Because the valve sleeves 13 seal the associated solenoid valves 11, the electronic control module 28 can be removed from the control valve 10 for servicing the electronic control components without disturbing the vehicle hydraulic brake system.

Summary of Invention

[0007] This invention relates to an electrical coil for a solenoid valve having electrical terminals extending in an axial direction from an interior portion thereof.

[0008] While the manufacture of an ECBS control valve is highly automated, may individual manufacturing steps are required. A number of these steps involve assembling the solenoid coils to the control valve. Typically, the coils must be positioned relative to the PCB. Then each of the coil terminals needs to be soldered to conductive traces formed upon the PCB, a time consuming and therefore expensive process. Accordingly, it would be desirable to provide a new solenoid coil design that would reduce the number of needed manufacturing steps.

[0009] The present invention contemplates a solenoid coil that includes a bobbin having an open ended axial bore formed therethrough. The bobbin also includes at least one terminal support extending from one end thereof in a direction parallel to the axial bore and having a portion extending over an end of the bobbin bore. The coil further has a terminal pin carried by the terminal support and a winding wound upon the bobbin.

[0010] In the preferred embodiment, the terminal pin is carried by the portion extending over the end of the bobbin bore whereby a tool inserted into the bore will support the terminal support and pin during assembly of the solenoid coil into an electrical apparatus. Also in the preferred embodiment, the terminal pin has a compliant end that is received by a via with an interference fit such that the pin is retained within the via and forms an electrical connection therewith.

[0011] The present invention also contemplates a method for assembling an electronic component comprising the steps of providing a solenoid coil that includes a bobbin having an open ended axial bore formed therethrough. The coil has at least one terminal support extending from one end thereof in a direction parallel to the axial bore and having a portion that extends over an end of the bobbin bore. The terminal support carries an electrical connector pin. The solenoid coil is placed over a support pin formed on a first tool with an end of the support pin contacting and supporting the terminal support portion extending over the bobbin bore. A printed circuit board having an aperture formed therethrough that corresponds to the electrical terminal pin is placed over the solenoid coil. A second tool presses the printed circuit board onto the electrical connector pin, the second tool cooperating with the first tool support pin to urge the electrical connector pin into the corresponding aperture formed through the printed circuit board with the electrical connector pin being retained therein.

[0012] In the preferred embodiment, the printed circuit board aperture is an electrical via and the end of the terminal pin includes a compliant connection portion. In this case, the compliant connector portion forms an interference fit with the via whereby the coil is retained upon the printed circuit board and an electrical connection is formed with a conductive trace deposited upon a surface thereof that terminates on the via. Alternately, the terminal pin may be fixed within the printed circuit board aperture by a conventional method, such as soldering the end of the pin to the conductive trace.

[0013] Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

Brief Description of Drawings

[0014] Fig. 1 is sectional view of a typical ECBS control valve that includes a prior art solenoid coil.

[0015] Fig. 2 is a perspective drawing of a solenoid coil in accordance with the present invention.

[0016] Fig. 3 is a plan view of the solenoid coil shown in Fig. 2.

[0017] Fig. 4 is a sectional view of an ECBS control valve that includes the solenoid coil shown in Fig. 2.

[0018] Fig. 5 is a flow chart for a method of assembling an electronic control unit that includes the coil shown in Fig. 2. [0019] Fig. 6 illustrates the tooling provided in the first step of the flow chart shown in Fig. 4.

[0020] Fig. 7 illustrates the second step of the flow chart shown in Fig. 4.

[0021] Fig. 8 illustrates the third step of the flow chart shown in Fig. 4.

[0022] Fig. 9 illustrates the fourth step of the flow chart shown in Fig. 4.

[0023] Fig. 10 illustrates the sixth step of the flow chart shown in Fig. 4.

[0024] Fig. 11 illustrates the last step of the flow chart shown in Fig. 4.

[0025] Fig. 12 is a sectional view of an ECBS control valve that includes the solenoid coil shown in Fig. 2 during the last step of the flow chart shown in Fig. 4.

[0026] Fig. 13 is another sectional view of an ECBS control valve during the last step in the flow chart shown in Fig. 4.

[0027] Fig. 14 illustrates an alternate embodiment of the solenoid coil shown in Fig. 2.

[0028] Fig. 15 illustrates the assembly of the solenoid coil shown in Fig. 12

[0029] Fig. 16 illustrates the solenoid coil shown in Fig. 12 disposed within a flux casing.

Detailed Description

[0030] Referring again to the drawings, there is illustrated in Fig. 2, a solenoid coil 30 in accordance with the present invention. As illustrated in Fig. 2, the coil 30 includes a winding 32 comprising a plurality of turns of fine wire wound upon a bobbin 34. The bobbin 34 is formed by a conventional method from an electrically non-conducting material, such as injection molding a plastic material. The bobbin 34 includes a cylindrical core having upper and lower end flanges, 36 and 38, respectively, formed upon the ends thereof.

[0031] A pair of terminal supports 40 extend in an axial direction from the upper surface of the upper bobbin end flange 36. As best seen in Fig. 3, each of the terminal supports 40 includes a offset portion 41 that extend in an inward radial direction over an open ended central axial bore 42 formed through the bobbin 30. A coil terminal 44 is carried by each of the terminal supports 40. As shown in Fig. 4, the lower end of each terminal 44 extends axially through the offset portion 41 of the corresponding terminal support 40. Components shown in Fig. 4 that are similar to components shown in Fig. 1 have the same numerical identifiers. While the terminal 44 is shown in Fig. 4 as extending through the offset portion 41, it will be appreciated that the invention also may be practiced with the lower end of the terminal 44 extending only partially into the upper portion of the offset portion (not shown). The lower ends of the terminals 44 are attached to the offset portions 41 by a convention process, such as for example, pressing the terminal ends into bores formed in the offset portions 41. Alternately, the terminal supports 40 could be molded over the ends of the terminals 44 when the bobbin 30 is formed. Each end of the winding coil wire is attached to a corresponding one of the coil terminals 44 (not shown) by a conventional method, such as, for example, winding the wire end about the terminal 44 in the area between the terminal support 40 and a Printed Circuit Board (PCB) 48 and then soldering the wire to the terminal 44. Alternately, the coil wire ends may be welded the coil terminals or a Insulation Displacement Connection (IDC) may be formed therebetween.

[0032] In the preferred embodiment, the upper end of each terminal 44 is formed as a compliant connector 46 that provides an electrical connection with a PCB 48. In the embodiment shown in Fig. 2, the compliant connector 46 consists of a widened portion of the terminal 44 that is below and spaced apart from the upper terminal end; however, it will be appreciated that the invention also may be practiced with other types of compliant connectors. The portion of the terminal end above the compliant connector 46 is slidingly received by a corresponding via formed through the PCB 48. The via is electrically connected to a trace deposited upon a surface of the PCB. Thus, the upper terminal end guides the coil 30 toward the PCB 48. As will be explained below, once the coil 30 is located relative to the PCB 48, the PCB is urged toward the coil. The urging forces the widended portion of the terminal 44 into the via with an interference fit to mechanically fix the coil 30 in place upon the PCB 48 and to form an electrical connection with the corresponding electrical trace. Additionally, the bobbin 34 includes a locating pin 50 that extends in an axial direction from the upper bobbin end flange 36. The locating pin 50 is received by a corresponding aperture formed through the PCB 48 as an aid in locating the coil 30 while enhancing the rigidity of the assembly. The coil 30 is enclosed within a flux casing 51. As best seen in Fig. 4, the terminal supports 40 and locating pin 50 extend through corresponding apertures formed through the flux casing 51. An annular flux ring 52 is disposed within the lower end of the flux casing 51. The flux ring 52 and flux casing 51 cooperate to provide a low reluctance return path for the magnetic flux field.

[0033] As will be explained below, the extension of the offset portions 41 of the terminal supports 40 places the ends of the terminals 44 over the bobbin bore 42 and allows insertion of an assembly tool through the bobbin bore 42 and directly against the end of the terminal. The tool presses the terminals 44 into associated vias formed through the PCB 48. As illustrated in Fig. 4, the end of each terminal 44 is received within a bore formed in a boss 53 that extends downward from an interior surface of a housing 54. As also shown in Fig. 4, compliant spacer 55.is disposed between the upper surface of the flux casing 51 and the lower surface of the PCB 48. The spacer 55 is formed from a resilient material such as rubber, silicon or foam. Alternately, a helical spring (not shown) may be used as a spacer. The spacer 55 applies a downward force upon the upper surface of the flux casing 55 to urge the casing and flux ring 56 against the solenoid valve 11 and thereby position the casing and ring for the most efficient transfer of magnetic energy to the valve cartridge armature.

[0034] The press assembly of the coil 30 to the PCB 48 results in more robust assembly, while also eliminating the need to solder the coil terminals to the traces formed upon the PCB. Additionally, less flux casing material needs to be removed, thus improving the magnetic performance of the valve. Finally, the design of the coil 30 permits greater packaging efficiency, with a resultant minimization of the volume within the housing 54 required for the coil. This, in turn, allows reduction of the size of the associated ECBS control valve.

[0035] The present invention also contemplates a method for assembling the coil 30 to a PCB 48 and housing 54. The method is illustrated by the flow chart shown in Fig. 5. The steps of the flow chart are further illustrated by Figs. 6 through 13. In functional block 60 a lower tooling 62, as shown in Fig. 6, is provided. As also shown in Fig. 6, the lower tooling 62 includes a plurality of cylindrical coil terminal supports 64 that extend perpendicularly from a base 65. The diameter of the supports 64 is selected such that the supports slidingly extend through the bores 42 of the coils 30 with the upper end of the supports contacting the lower surface of the coil's terminal support offset portions 41. The supports 64 are located upon the base 65 to position the coils relative to the PCB 48. Additionally, the lower tooling 62 includes a generally rectangular PCB support block 66 that has a plurality of bores 67 formed in the upper surface thereof. As will be explained below, the bores 67 are positioned to receive the ends of electrical connector pins. The lower tooling 62 further includes a plurality of housing guide pins 68 extending perpendicularly from the base 65. The housing guide pins 68 are used to guide the housing 54 into position over the PCB 48 and coils 30.

[0036] The method proceeds to functional block 70, where a coil assembly 72 comprising a coil 30, flux casing 51 and flux ring 56 is placed over each of the coil terminal supports 64, as illustrated in Fig. 7. In the preferred embodiment, the coil assemblies 72 are placed upon the supports 64 by a mechanism (not shown) that aligns the coil terminals 44 and locating pins 50 relative to the corresponding PCB vias and apertures. Alternately, other conventional keying means could be used to properly align the coil assemblies 72 upon the supports 64, such as, for example, an axial slot formed in the interior surface of the flux ring could receive a rib formed upon the base of the coil support (not shown). Once the coil assemblies 72 are placed upon the supports 64, the compliant spacers 55 are placed upon the centers of the flux casings 51. Alternately, the compliant spacers 55 may be attached to the flux casings by a conventional method, such as adhesive bonding, before the coil assemblies 72 are placed upon the coil terminal supports 64.

[0037] Continuing to functional block 74, the PCB 48 is placed over the coil assemblies 72, as shown in Fig. 8. Although not shown in Fig. 8, the invention also contemplates providing locating devices, such as pins, upon the lower tooling 62 to position the PCB 48 upon the tooling. As the PCB 48 is placed upon the tooling, the upper ends of the coil terminals 44 extend through corresponding vias formed therethrough; however, the wider portions of the terminal ends prevent the PCB 48 from reaching its final spacing above the coil assemblies 72. As also shown in Fig. 8, the upper ends of the bobbin locator pins 50 extend through corresponding apertures formed through the PCB 48. [0038] During the next step, shown in functional block 76 in Fig. 5, a first upper tool 78 is pressed against the upper surface of the PCB 48, as illustrated in Fig. 9 by the arrow labeled 79. In the preferred embodiment, a force of 150 Newtons (Nt) is applied to the PCB 48 for each of the terminal pins 44; however, it will be appreciated that more or less force may be applied, as determined by the dimensions of the terminal pin and the receiving via. Thus, for the preferred embodiment, a typical assembly of eight coils would require that a force of approximately 2500 Nt be applied by the first upper tool 78 to the PCB 48. The first upper tool 78 includes a plurality of cylindrical bosses 80 having central axial bores. As the tool 78 is pressed against the PCB 48, the bores in the bosses 80 receive the upper ends of the coil terminals 44 while the boss end surfaces contact the upper surface of the PCB 48. The end surfaces of the bosses 80 press the PCB 48 in a downward direction in Fig. 9 and against the PCB support block 66. As the PCB 48 is pressed downward the compliant connector 46 portions of the coil terminals 44 are forced into the corresponding PCB vias to form interference fits therebetween. As the widended portions 46 of the coil terminals 44 are pressed into the vias, the lower tooling coil terminal supports 64 provide support to the lower ends of the terminal pins 44. The interference fit provides both a solderless electrical connection to the vias while securing the coil assemblies 72 upon the PCB 48.

[0039] The method then continues to functional block 82 where the first upper tooling 78 is withdrawn. Then, in functional block 84, the housing 54 is placed over the PCB 48 and coil assemblies. The housing 54 is located upon the lower tooling 62 by the housing guide pins 68, as shown in Fig. 10. As shown in Figs. 10 and 13, in the preferred embodiment, the housing 54 includes a male electrical connector 86 for connecting the ECBS control valve to other vehicle components. The connector 86 typically includes both blade and pin connectors 88 and 90, respectively having compliant lower ends 89 and 91, respectively. As shown in Fig. 13, the connectors 88 and 90 are pressed through apertures formed through a connector base 92 to form a connector assembly 94 with the connectors 88 and 90 extending perpendicularly from both the upper and lower surfaces of the base 92. The housing 54 is then overmolded over the connector assembly 94. Alternately, the connectors 88 and 90 may be placed into a housing mold and the housing 54 overmolded directly over the conectors (not shown). Also, as described above, and shown in Fig. 12, a plurality of bosses 53 are formed upon the interior surface of the housing top surface that extend downward. Each of the bosses 53 has an axial bore formed therein and is located within the housing 54 such that each of the bores receives the upper end of an associated coil terminal 44. The diameter of the boss bore is less than the width of the terminal end so that an interference fit is provided therebetween.

[0040] Finally, in functional block 96, a second upper tooling 97 presses the housing 54 against the PCB 54, as shown in Fig. 11. The second upper tooling 97 includes a first portion 98 that provides mechanical staking of the ends of the coil terminals 44 into the internal housing bosses 53. The tooling 97 also includes a second portion 100 that supports the blade and pin connectors 88 and 90 carried by the electrical connector 86 during the housing assembly operation of functional block 96. The pressure of the tooling 98 forces the ends of the coil terminals 44 into the associated bores formed in the housing bosses 53 extending from the lower surface of the top of the housing 54, thereby staking the coil terminals 44 into bosses 52. The staking of the coil terminals 44 into the bosses 52 secures the PCB 48 and the coil assemblies 72 within the housing 54 and is illustrated in the sectional view shown in Fig. 12. Also, the staking provides support to the coils 30 within the housing 54 while removing any mechanical loading from the compliant pin connection joints. The assembly also provides an air gap between the PCB 48 and the housing 54. [0041] As best seen in Fig. 13, the second portion 100 of the tooling 97 extends into the electrical connector 86. A plurality of bores 102 extend perpendicularly into the lower surface of the tool second portion 100. The tool bores receive the upper ends of the electrical connector pins and blades, 88 and 90, allowing the lower surface of the tool portion 100 to contact the base of the connector 86. Thus, as the second upper tooling 98 presses the housing toward the PCB 48 and coil assemblies 72, the connector portion 100 presses the compliant lower ends 89 and 91 of the connectors 88 and 90 through the associated vias formed through the PCB 48. The ends of the connectors 88 and 90 extend into corresponding bores 67 formed in the PCB support block 66 included in the lower tooling 62. The interference fit between the connector ends 89 and 91 and the vias both forms a solderless electrical connection and secures the connectors 88 and 90 to the ECB 48.

[0042] By integrating an interference fit between the coil terminals 44 and a bore in the housing boss 52, the coils 30 can be mechanically fixed to the housing 54, eliminating the need for an additional component to retain the coils 30 within the housing 54. Additionally, the mechanical fixing of the coils 30 and the electrical connectors 88 and 90 to the PCB 48 eliminates the need to solder the coil terminals and connectors to the PCB 48, thereby simplifying and reducing the time and cost needed for assembly.

[0043] The present invention further contemplates an alternate embodiment 110 of the coil that is illustrated in Fig. 14. Components shown in Fig. 14 that are similar to components shown iiϊthe other figures have the same numerical identifiers. The coil 110 includes a single terminal support 112 that extends in an axial direction from the upper bobbin end flange 36. As best seen in Fig. 15, the terminal support 112 includes a pair of recesses 114 that receive a pair of compliant connector pins 116. Each of the pins 116 includes a connector pin slot 118 and a pair of barbs 120 formed in the lower end thereof with the slot

118 extending between the barbs 120. When the connector pins 116 are initially inserted into the terminal support recesses 114, the connector pin slot 118 allows compression of the barbs 120 toward one another. As the connector pins 116 are further inserted into the recesses 114, the barbs 120 extend outward into locking recesses (not shown) formed within the recesses 114 to secure the pins 116 within the support recesses 112.

[0044] As also shown in Fig. 15, a radially extending terminal support slot

119 is formed in the end of each recess 114. The invention contemplates that, as shown in Fig. 14, the ends 122 of the coil winding 32 extend through notches 124 formed in the outer edge of the upper bobbin flange 36 and are received by the terminal support slots 119 with the coil ends extending across the recesses

114. Accordingly, as the connector pins 116 are inserted into the recesses 114, the coil winding ends 122 are received within the connector pin slots 118 to form an electrical connection between the coil winding 32 and the connector pins 116. The upper ends 128 of the connector pins 116 are formed as compliant connectors having a central cavity that collapses when pressed into a via formed through a PCB (not shown) to form an interference fit. As shown in Fig. 16, the coil 110 is disposed within a flux casing 130.

[0045] The invention further contemplates that the terminal support 112 may include an offset portion that extends over the end of the bobbin bore, similar to the embodiment described above (not shown). The portion would be supported by a tool as described above as the coil is assembled to a PCB. Additionally, the recesses may located in the offset portion, as also described above, to provide direct support to the connector pins.

[0046] The use of the compliant pin 104 eliminates soldering of the coil wire to the terminal pins, as shown in the prior art coil of Fig. 1. The use of the compliant pin 104 also eliminates the soldering of the pin to the PCB. Thus, the coil 90 reduces assembly time and costs.

[0047] While the preferred embodiment has been illustrated and described as including terminal pins having compliant ends, it will be appreciated that the invention also may be practiced using conventional terminal pins (not shown). In such a case, the terminal pins would be secured to the PCB by a conventional method, such as, for example soldering the terminal pin end to a conductive trace formed upon a PCB surface or within a via formed through the PCB.

[0048] The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. For example, the terminal supports 40 of the coil 30 shown in Figs. 2 through 4 may be formed with recesses 94 and locking recesses similar to those shown in Figs. 14 and 15 to receive compliant terminal pins 96 similar to those shown in Figs. 14 and 15. Similarly, the compliant ends of the terminal pins shown in Figs. 14 and 15 may be substituted for the compliant ends of the terminal pins shown in Figs. 2 through 4.

Claims

ClaimsWhat is claimed is:

1. A solenoid coil comprising: a bobbin having an open ended axial bore formed therethrough, said bobbin having at least one terminal support extending from one end thereof in a direction parallel to said axial bore, said terminal support having a portion extending over an end of said bobbin bore; a terminal pin carried by said terminal support; and a winding wound upon said bobbin.

2. The solenoid coil according to clam 1 wherein said terminal pin is carried by said portion of said terminal support that extends over said end of said bobbin bore.

3. The solenoid coil according to claim 2 wherein said terminal pin includes a compliant electrical connector.

4. The solenoid coil according to claim 3 wherem said bobbin has a plurality of terminal supports extending from one end thereof in a direction parallel to said axial bore, each of said terminal supports having a portion that extends over an end of said bobbin bore and further wherein each of said support portions that extend over said bobbin bore end carries terminal pin that includes a compliant electrical connector.

5. The solenoid coil according to claim 4 further including at least one locator pin extending from one end thereof in a direction parallel to said axial bore.

6. A method for assembling an electronic component comprising the steps of:

(a) providing a solenoid coil that includes a bobbin having an open ended axial bore formed therethrough and at least one terminal support extending from one end thereof in a direction parallel to the axial bore, the terminal support having a portion extending over an end of the bobbin bore, the terminal support carrying an ele'ctrical connector pin;

(b) placing the solenoid coil over a support pin formed on a first tool, an end of the support pin contacting and supporting the terminal support portion extending over the bobbin bore;

(c) placing a printed circuit board over the solenoid coil, the printed circuit board having an aperture formed therethrough that corresponds to the electrical terminal pin carried by the coil terminal support; and

(d) using a second tool to press the printed circuit board onto the electrical connector pin, the second tool cooperating with the first tool support pin to urge the electrical connector pin into the corresponding aperture formed through the printed circuit board with the electrical connector pin being retained therein.

7. The method according to claim 6 wherein the aperture is a via and further wherein the end of the electrical connector pin has a compliant portion that is received by and retained within the via by an interference fit, the compliant portion forming an electrical connection with a conductive trace deposited upon the printed circuit board that terminates upon the via.

8. The method according to claim 7 wherein the compliant portion of the electrical connector pin is spaced apart from the end of the pin and the second tool has a bore formed in the surface thereof that is adjacent to the solenoid coil terminal support such that the end of the electrical connector pin extends through the printed circuit board via and is received by the bore formed in the second tool surface.

9. The method according claim 6 further including the further steps of: (e) removing the second tool; (f) placing a housing having at least one boss formed upon the inner surface thereof over the printed circuit board and coil, the boss including a bore formed therein that corresponds to the coil electrical connector pin; and (g) using a third tool to press the housing onto the printed circuit board, the end of the electrical connector pin being received by the bore formed in the housing boss and forming an interference fit therewith to secure the coil and printed circuit board within the housing.

10. The method according to claim 9 further including, between steps (b) and (c), placing a flux casing over the solenoid coil.

11. The method according to claim 6 wherein the housing includes an electrical connector having at least one electrical connecting pin extending therefrom and further wherein, during step (g) the third tool urges the end of the electrical connector pin into a corresponding aperture formed through the printed circuit board, the end of the electrical connector pin being retained within the via and forming an electrical connection with a conductive trace deposited upon the printed circuit board.

12. The method according to claim 11 wherein the aperture is a via and further wherein the housing electrical connector pin has a compliant connection formed upon the end thereof that is urged into the via formed through the printed circuit board, the compliant connection cooperating with the via to retain the connector in the via and form an electrical connection with the printed circuit board conductive trace.

13. The method according to claim 6 further including the steps of removing the second tool and then soldering the end of the connector pin to a conductive trace deposited upon a surface of the printed circuit board.

14. The method according to claim 11 wherein the end of the electrical connector pin is soldered to a conductive trace deposited upon a surface of the printed circuit board.

15. A solenoid coil comprising: a bobbin having an axial bore formed therethrough, said bobbin having at least one terminal support extending axially from one end thereof, said terminal support having at least one recess formed therein, said recess including a pair of locking recesses formed therein; a terminal pin carried by said terminal support recess, said terminal pin including a pair of barbs formed upon an end thereof, said barbs being received by said locking recesses with each of said barbs extending into a corresponding one of said locking recesses to secure said terminal pin within said recess; and a winding wound upon said bobbin.

16. The coil according to claim 15 wherein said terminal pin includes a slot formed therein between said barbs, said slot allowing compression of said barbs upon said pin being inserted into said recess and further wherein said slot allows said barbs to extend into said locking recesses.

17. The coil according to claim 16 wherein said connector pin also includes a compliant end opposite from said barbed end, said compliant end adapted to form an interference fit with a corresponding via formed through a printed circuit board.

18. The coil according to claim 17 wherein said terminal support also has a slot formed in the end thereof that extends across said recess, and further wherein an end of said coil winding extends through said terminal support slot and is received by said terminal pin slot whereby an electrical connection is made between said tenninal pin and said coil winding end and said coil winding end is retained within said terminal support slot.

19. The coil according to claim 18 wherein said terminal support recess is first recess and said terminal pin is first terminal pin and further wherein said terminal support has a second recess formed therein that receives a barbed end of a second terminal pin.

20. The coil according to claims 18 wherein said second terminal support recess support also has a slot formed in the end thereof that extends across said recess, and further wherein a second end of said coil winding extends through said terminal support slot and is received by a slot formed in the end of said second terminal pin whereby an electrical connection is made between said second terminal pin and said second coil winding end and said second coil winding end is retained within said terminal support slot.

21. The coil according to claim 20 wherein said terminal support includes a portion that extends over an end of said bobbin bore.