Solenoid having inverse tapered armature for solenoid-actuated valve

Patent metadata

Field	Value
Publication number	US-11201005-B2
Application number	US-201616313963-A
Country	US
Kind code	B2
Filing date	Jun 28, 2016
Priority date	Jun 28, 2016
Publication date	Dec 14, 2021
Grant date	Dec 14, 2021

Abstract

A solenoid ( 54 ) for a solenoid-actuated valve ( 30 ) includes a sintered powder metal one-piece core ( 64 ) of at least one soft magnetic material and at least one non-magnetic material integrally connected together and a movable armature ( 88 ) disposed in the core ( 64 ) and having a tapered tip to achieve a required force vs position and current characteristics.

First claim

What is claimed is:

1. A solenoid ( 54 ) for a solenoid-actuated valve ( 30 ), said solenoid comprising:
a sintered powder metal one-piece core ( 64 ) comprised of at least one soft magnetic material and at least one non-magnetic material integrally connected together; and
a movable armature ( 78 ) disposed in said core ( 64 ) and having a tapered tip including an inverse tapered shunt ( 80 ) to achieve a required force vs position and current characteristics, wherein a tapered portion of said moveable armature ( 78 ) tapers away from an inside diameter of said moveable armature ( 78 ) and towards an outside diameter of said moveable armature ( 78 ), wherein a force shaping taper on said movable armature ( 78 ) allows for a perpendicular material interface of said sintered powder metal one-piece core ( 64 ).

2. The solenoid ( 54 ) as set forth in claim 1 wherein said armature ( 78 ) is coated with high phosphorus electroless nickel plating to provide a sliding bearing surface and to provide physical separation of magnetic material of said armature ( 78 ) from said magnetic material of said core ( 64 ).

3. The solenoid ( 54 ) as set forth in claim 1 wherein said armature ( 78 ) is coated with fluoropolymer coating to provide a sliding bearing surface to provide physical separation of magnetic material of said armature from said magnetic material of said core ( 64 ).

4. The solenoid ( 54 ) as set forth in claim 1 wherein said sintered powder metal one-piece core ( 64 ) includes a flux tube ( 68 ), a pole piece ( 66 ) spaced axially from said flux tube ( 68 ), and a flux choke ( 70 ) integrally connecting said flux tube ( 68 ) and said pole piece ( 66 ) together, wherein said flux choke ( 70 ) is comprised of austenitic stainless steel and said pole piece ( 66 ) and said flux tube ( 68 ) are comprised of phosphorus iron.

5. The solenoid ( 54 ) as set forth in claim 1 wherein said sintered powder metal one-piece core ( 64 ) includes a flux tube ( 68 ), a pole piece ( 66 ) spaced axially from said flux tube ( 68 ), and a flux choke ( 70 ) integrally connecting said flux tube ( 68 ) and said pole piece ( 66 ) together, wherein said flux choke ( 70 ) is comprised of austenitic stainless steel and said flux tube ( 68 ) and said pole piece ( 66 ) are comprised of cobalt iron.

6. The solenoid ( 54 ) as set forth in claim 1 including a coil ( 60 ) disposed about said core ( 64 ).

7. The solenoid ( 54 ) as set forth in claim 6 including at least one terminal ( 62 ) connected to said coil ( 60 ).

8. The solenoid ( 54 ) as set forth in claim 6 wherein said coil ( 60 ) is made of copper wire.

9. The solenoid ( 54 ) as set forth in claim 6 including a can ( 56 ) disposed about said coil ( 60 ).

10. A solenoid ( 54 ) for a solenoid-actuated valve ( 30 ), said solenoid ( 54 ) comprising:
a sintered powder metal one-piece core ( 64 ) comprised of at least one soft magnetic material and at least one weakly magnetic material integrally connected together; and
a movable armature ( 78 ) disposed in said core ( 64 ) and having a tapered tip including an inverse tapered shunt ( 80 ) to achieve a required force vs position and current characteristics, wherein a tapered portion of said moveable armature ( 78 ) tapers away from an inside diameter of said moveable armature ( 78 ) and towards an outside diameter of said moveable armature ( 78 ), wherein a force shaping taper on said movable armature ( 78 ) allows for a perpendicular material interface of said sintered powder metal one-piece core ( 64 ).

11. The solenoid ( 54 ) as set forth in claim 10 wherein said armature ( 78 ) is coated with high phosphorus electroless nickel plating to provide a sliding bearing surface and to provide physical separation of magnetic material of said armature ( 78 ) from said magnetic material of said core ( 64 ).

12. The solenoid ( 54 ) as set forth in claim 10 wherein said armature ( 78 ) is coated with fluoropolymer coating to provide a sliding bearing surface to provide physical separation of magnetic material of said armature from said magnetic material of said core ( 64 ).

13. The solenoid ( 54 ) as set forth in claim 10 wherein said sintered powder metal one-piece core ( 64 ) includes a flux tube ( 68 ), a pole piece ( 66 ) spaced axially from said flux tube ( 68 ), and a flux choke ( 70 ) integrally connecting said flux tube ( 68 ) and said pole piece ( 66 ) together, wherein said flux choke ( 70 ) is comprised of austenitic stainless steel and said pole piece ( 66 ) and said flux tube ( 68 ) are comprised of phosphorus iron.

14. The solenoid ( 54 ) as set forth in claim 10 wherein said sintered powder metal one-piece core ( 64 ) includes a flux tube ( 68 ), a pole piece ( 66 ) spaced axially from said flux tube ( 68 ), and a flux choke ( 70 ) integrally connecting said flux tube ( 68 ) and said pole piece ( 66 ) together, wherein said flux choke ( 70 ) is comprised of austenitic stainless steel and said flux tube ( 68 ) and said pole piece ( 66 ) are comprised of cobalt iron.

15. A solenoid-actuated valve ( 30 ) comprising:
a solenoid ( 54 );
a valve body ( 32 ) connected to and operatively associated with said solenoid ( 54 );
a valve ( 34 ) axially and slidingly disposed within said valve body ( 32 );
said solenoid ( 54 ) comprising a sintered powder metal one-piece core ( 64 ) comprised of at least one soft magnetic material and at least one non-magnetic material integrally connected together and a movable armature ( 78 ) disposed in said core ( 64 ) and having a tapered tip including an inverse tapered shunt ( 80 ) to achieve a required force vs position and current characteristics, wherein a tapered portion of said moveable armature ( 78 ) tapers away from an inside diameter of said moveable armature ( 78 ) and towards an outside diameter of said moveable armature ( 78 ); and
wherein said sintered powder metal one-piece core ( 64 ) includes a flux tube ( 68 ), a pole piece ( 66 ) spaced axially from said flux tube ( 68 ), and a flux choke ( 70 ) integrally connecting said flux tube ( 68 ) and said pole piece ( 66 ) together, and
wherein a force shaping taper on said movable armature ( 78 ) allows for a perpendicular material interface of said sintered powder metal one-piece core ( 64 ).

16. The solenoid ( 54 ) as set forth in claim 4 , wherein said flux choke ( 70 ) has a rectangular cross-section.

Assignees

• Borgwarner Inc

Inventors

• Deland Daniel L

Classifications

• H01F7/1607

  Armatures entering the winding · CPC title

• H01F2007/086

  Structural details of the armature · CPC title

• H01F7/081 Primary

  Magnetic constructions · CPC title

• H01F3/10

  Composite arrangements of magnetic circuits · CPC title

• H01F7/13

  characterised by pulling-force characteristics · CPC title