Armature for valve actuation and method of manufacturing armature

Abstract

An armature for use in an armature assembly associated with actuation of valves, such as for fuel injectors, fuel cells and / or fuel pumps, is disclosed. The armature includes a body having: a first end having a flange; and a shaft extending from the flange to the second end of the body. The second end portion includes a recessed surface configured to reduce stress on the armature upon an impact. The armature may be made of a low strength material of high permeability, thereby reducing remanence in the armature, assisting in demagnetization release, and reducing delay at the end of ejection.

Description

Technical Field

[0001] This disclosure relates in general to armature assemblies for valve actuation, such as in fuel injectors, fuel cells and / or fuel pumps, and more particularly to armatures used in such armature assemblies and the manufacture of such armatures. Background Technology

[0002] Armatures can be used in armature assemblies that actuate valves using solenoids, such as those used in fuel injectors, fuel cells, fuel pumps, and / or fluid flow control devices. Armatures can be manufactured by machining one or more pieces of blank metal material to form the desired configuration, size, and surface finish. The machining process involves the manufacturing time for producing each armature component, as well as energy input, material waste, and facility cleaning. Therefore, armatures assembled from multiple components are more expensive than those machined as a single piece. Furthermore, because the armature material required to provide the necessary stress resistance within the armature has residual magnetism, the armature may cause a delayed shut-off of the fuel injector at the end of injection. Therefore, further improvements are needed in this area.

[0003] Disclosure of exemplary embodiments To clearly, concisely, and accurately describe the exemplary embodiments of this disclosure, their formulation and use, and to enable the practice, formulation, and use of these exemplary embodiments, reference will now be made to certain exemplary embodiments (including those illustrated in the accompanying drawings), and these embodiments will be described using specific language. However, it should be understood that this does not limit the scope of the invention, and the invention includes and protects such changes, modifications, and further applications of the exemplary embodiments that can be conceived by those skilled in the art. Summary of the Invention

[0004] An armature for use in an armature assembly associated with actuation of valves such as those used in fuel injectors, fuel cells, and / or fuel pumps is disclosed. The armature includes a body having: a first end having a flange; and a shaft extending from the flange to a second end of the body. The second end includes a recessed surface configured to reduce stress on the armature upon impact. The armature may be made of a highly permeable, low-strength material to reduce residual magnetism in the armature, aiding in demagnetization release and reducing delay at the end of injection.

[0005] In one embodiment of this disclosure, an armature is provided, the armature including a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located at the first end; and a shaft extending from the flange. The shaft extends along the longitudinal axis from the flange to the second end of the body. The body includes a channel extending along the longitudinal axis. The channel opens at both the first and second ends of the body. The second end of the body includes an end surface extending around the channel. The end surface has a first portion extending around the second portion. The first portion of the end surface is flat, and the second portion of the end surface is recessed from the first portion toward the first end of the body.

[0006] In another embodiment of this disclosure, a method for manufacturing an armature for actuating a valve is provided. The method includes the steps of: forming a monolithic metal body using a metallic material and a metal injection molding process and / or a bar forming process. The monolithic metal body is formed to include: a flange located at a first end of the monolithic metal body; and a shaft extending from the flange along a longitudinal axis. The shaft extends to a second end of the monolithic metal body opposite the first end. A channel extending along the longitudinal axis opens at both the first and second ends of the monolithic metal body.

[0007] This invention is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help limit the scope of the claimed subject matter. Further embodiments, forms, objects, features, advantages, aspects, and benefits will become apparent from the following description and drawings. Attached Figure Description

[0008] The description herein refers to the accompanying drawings, wherein the same reference numerals in the various views refer to the same parts, and wherein: Figure 1 This is a schematic diagram illustrating certain aspects of an armature according to an exemplary embodiment of the present disclosure.

[0009] Figure 2 yes Figure 1 A longitudinal sectional view of the armature.

[0010] Figure 3 yes Figure 1 An enlarged cross-sectional view of a portion of the armature.

[0011] Figure 4 This is a schematic diagram of a metal injection molding process and / or bar processing process for manufacturing an armature according to embodiments of the present disclosure.

[0012] Figure 5This is a schematic flowchart of a process for forming an armature using a metal injection molding process according to an embodiment of the present disclosure.

[0013] Figure 6 This is a cross-sectional view of an example fuel injector for an internal combustion engine, which includes... Figure 1 The armature. Detailed Implementation

[0014] The following detailed description is taken in conjunction with the accompanying drawings, which are an integral part of the description and illustrate, by way of example, specific embodiments in which the present disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure. It should be understood that other embodiments may be used and structural changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description should not be considered limiting, and the scope of the present disclosure is defined by the appended claims and their equivalents.

[0015] Figures 1 to 3 This is an example associated with the armature 100 according to an embodiment of the present disclosure. Figure 4 It is a schematic diagram of the manufacturing process used for armatures, and Figure 5 This is a flowchart of a method for manufacturing an armature 100 using a metal injection molding process according to an embodiment of the present disclosure. Figure 6 This is a detailed cross-sectional view of an embodiment of fuel injector 200 to illustrate an exemplary specific implementation of the armature 100 in the valve 250 of a particular fuel injector. While this disclosure describes specific configurations of the fuel injector 200 and / or the armature 100, one or more of those features described in this disclosure may be omitted, and other features are not excluded. The armature 100 of this disclosure can be used in any fuel injector, fuel cell, fuel pump, and / or flow control valve compatible with the features of this disclosure.

[0016] As shown in these figures, in an embodiment of this disclosure, armature 100 includes a body 102 extending along a longitudinal axis L between a first end 104 and an opposing second end 106. Body 102 includes a flange 108 located at the first end 104 and a shaft 110 extending from the flange 108. Shaft 110 extends along the longitudinal axis L from the flange 108 to the second end 106 of body 102. Body 102 includes a channel 112 extending along the longitudinal axis L. Channel 112 opens at the first end 104 and the second end 106 of body 102. The second end 106 of body 102 includes an end surface 114 extending around channel 112. End surface 114 has a first portion 116 extending around a second portion 118. The first portion 116 of end surface 114 is flat, and the second portion 118 of end surface 114 is recessed from the first portion 116 toward the first end 104 of body 102.

[0017] In another embodiment of this disclosure, a method 400 for manufacturing an armature 100 for actuating purposes of a valve is provided. Method 400 includes step 404: forming a monolithic metal body 102 using a metallic material and metal injection molding and / or bar forming processes. The monolithic metal body 102 is formed to include: a flange 108 located at a first end 104 of the monolithic metal body 102; and a shaft 110 extending from the flange 108 along a longitudinal axis L. The shaft 110 extends to a second end 106 of the monolithic metal body 102 opposite to the first end 104. A channel 122 extends along the longitudinal axis L and opens at the first end 104 and the second end 106 of the monolithic metal body 102.

[0018] refer to Figures 1 to 2 The armature 100 includes a body 102 extending along a longitudinal axis L from a first end 104 to a second end 106. The body 102 includes a flange 108 located at the first end 104 and a shaft 110 extending from the flange 108 to the second end 106. The flange 108 extends radially outward from and perpendicular to the shaft 110. The flange 108 includes an outer edge 120 forming a circular shape, the flange 108 projects radially outward from a channel 112, and the shaft 110 extends axially from one side of the flange 108. In an embodiment, the flange 108 is disk-shaped and the shaft 110 is cylindrical, and the channel 112 extends longitudinally along the longitudinal axis L through the flange 108 and the shaft 110.

[0019] In one embodiment, the flange 108 includes an outer diameter defined by an outer edge 120, which is larger than a maximum outer diameter portion defined by the outer surface of the shaft 110. The flange 108 includes a plurality of slots 122 extending through the flange 108. Each of the plurality of slots 122 extends radially inward from the outer edge 120 of the flange 108 to a terminal end 124 of a corresponding slot. In one embodiment, the plurality of slots 122 consists of four slots 122 spaced at equal angles around the flange 108.

[0020] In one embodiment, the flange 108 includes an end surface at a first end 104 of the body 102, the end surface including an outer end face portion 126 and a recessed end face portion 128. The recessed end face portion 128 extends around the channel 112, and the outer end face portion 126 extends around the recessed end face portion 128. The outer end face portion 126 may be planar and / or include one or more surfaces 126a, 126b offset from each other.

[0021] A recessed end face portion 128 at the first end portion 104 is radially spaced inward from the outer end face portion 126. The recessed end face portion 128 is offset from the outer end face portion 126 toward the second end portion 106 into the body 102. In an embodiment, the flange 108 also includes a second face 132 opposite to the outer end face portion 126. The second face 132 faces the second end portion 106 and extends radially outward from the shaft 110. In an embodiment, a plurality of through holes 130 in the flange 108 extend through the outer end face portion 126 and the second face 132.

[0022] In one embodiment, flange 108 includes a first flange portion 134 extending radially outward from shaft 110, the first flange portion having a first thickness t1 between an outer end face portion 126 and a second face 132. Flange 108 also includes a second flange portion 136 between adjacent pairs of slots 122. The second flange portion 136 extends radially outward from the first flange portion 134 to the outer edge 120 of flange 108. The second flange portion 136 gradually thins from the first thickness t1 to a second smaller thickness t2, the second smaller thickness being located between the outer end face portion 126 and the second face 132 at the outer edge 120 of flange 108. Using slots 122 and / or the gradually thinning second flange portion 136 to reduce the mass of flange 108 facilitates movement of armature 100 during valve opening and closing operations.

[0023] In one embodiment, the flange 108 includes a plurality of holes 130, each extending radially through the outer end face portion 126 and the second face 132. Each of the plurality of holes 130 is located between a corresponding pair of slots 122. In the illustrated embodiment, the holes 130 are cylindrical, but other shapes of the holes 130 are also contemplated. In one embodiment, the holes 130 are equiangularly spaced from each other about the longitudinal axis L around the flange 108. Similarly, the slots 122 may be equiangularly spaced about the longitudinal axis L at the same angle around the flange 108, but are positioned such that each hole 130 is located between a corresponding pair of slots 122. Other embodiments contemplate fewer than four holes 130 and / or slots 122, or more than four holes 130 and / or slots 122.

[0024] In this embodiment, the orifice 130 is a diffuser orifice that influences fluid flow at all points during the travel of the armature 100. During travel of the armature 100 toward the first end 104, fluid on the outer end face portion 126 is compressed and may cause high-pressure spikes. The presence of the diffuser orifice 130 and / or the slot 122 helps diffuse these pressure spikes during armature travel, thereby increasing the speed of the armature 100. During travel of the armature 100 toward the second end 106, fluid flows through the diffuser orifice 130 from the second face 132 of the flange 108 to the outer end face portion 126, thereby reducing hydraulic resistance on the armature 100 and increasing speed.

[0025] Further reference Figure 3 In one embodiment, channel 112 includes: a first diameter D1 adjacent to a second end 106 of body 102; and a second diameter D2 distributed along a large portion of the length of channel 112 between the first end 104 and the second end 106 of body 102. The first diameter D1 of channel 112 is larger than the second diameter D2 of channel 112. In one embodiment, a lip 140 connects the transition region from diameter D1 to diameter D2. In one embodiment, the lip 140 is oriented at an oblique angle to the longitudinal axis L.

[0026] In one embodiment, the shaft 110 of the body 102 includes an outer surface 142 extending from the flange 108 to the second end 106. The outer surface 142 extends from the second end 106 of the body 102 to a second face 132 of the flange 108. In one embodiment, the outer surface 142 has a stepped surface profile along a portion of the length of the shaft 110.

[0027] In one embodiment, the stepped surface profile of the outer surface 142 of the shaft 110 includes a first shaft portion 144 adjacent to the flange 108 and having a first outer diameter OD1. The stepped surface profile also includes a second shaft portion 146 adjacent to the first shaft portion 144. The second shaft portion 146 includes a second outer diameter OD2 smaller than the first outer diameter OD1. The stepped surface profile of the outer surface 142 of the shaft 110 includes a third shaft portion 148 adjacent to the second shaft portion 146. The third shaft portion 148 extends to a second end 106 of the body 102. The third shaft portion 148 has a third outer diameter OD3 smaller than the second outer diameter OD2.

[0028] The second end portion 106 includes an end surface 114 extending about a longitudinal axis L. The end surface 114 includes a first portion 116 extending about a second portion 118. In an embodiment, the first portion 116 is flat and / or orthogonal to the longitudinal axis L. The second portion 118 is recessed from the first portion 116 toward the first end portion 104 of the body 102. The recessed configuration of the end surface 114 reduces stress on the second end portion 106 and the shaft 110 as the armature 100 travels toward the second end portion 106 to contact the stop surface during actuation of the armature 100. In an embodiment, the stress reduction at the first end portion 106 allows the armature 100 to be made of a highly permeable, low-strength material, reduces residual magnetism in the armature 100 to aid in demagnetizing and releasing the armature 100 from its magnetic connection with the solenoid, and reduces delay at the end of ejection.

[0029] In one embodiment, the second portion 118 of the end surface 114 is planar and / or oriented at a taper angle A1 to the first portion 116 and / or the longitudinal axis L. In another embodiment, the second portion 118 of the end surface 114 gradually narrows from the first portion 116 at a taper angle A1 of 0.1 to 4 degrees to provide a concave configuration for stress reduction. In yet another embodiment, the second portion 118 of the end surface 114 gradually narrows from the first portion 116 at a taper angle A1 of 0.1 to 1 degree to provide a concave configuration for stress reduction. In yet another embodiment, the second portion 118 of the end surface 114 gradually narrows from the first portion 116 at a taper angle A1 of approximately 0.5 degrees plus or minus 0.4 degrees to provide a concave configuration for stress reduction. Other embodiments envision non-planar configurations of the second portion 118 of the end surface 114, such as concave surfaces and / or non-planar configurations.

[0030] In one embodiment, a first portion 116 of the end surface 114 has an outer diameter D3 and an inner diameter D4. The first portion 116 defines a contact area between the outer diameter D3 and the inner diameter D4. A second portion 118 has an outer diameter D4 that coincides with the inner diameter D4 of the first portion 116, and an inner diameter D1 that coincides with the diameter of the channel 112. The second portion 118 defines a recessed area between the diameters D1 and D4.

[0031] In one embodiment, the area ratio of the second portion 118 to the area of ​​the first portion 116 is 4 to 7, such that the contact area and stress distribution at the end surface 114 are better distributed along the second portion 118 and the first portion 116. In another embodiment, the area ratio of the second portion 118 to the area of ​​the first portion 116 is between 5 and 6, such that the contact area and stress distribution at the end surface 114 are better distributed along the second portion 118 and the first portion 116.

[0032] refer to Figure 4 This illustration shows a schematic diagram of a metal injection molding process and / or bar forming process 300 for molding and / or bar forming an armature 100 to form the disclosed configuration. Process 300 includes a raw material 302 of metal material. In an embodiment, the raw material 302 is a powdered metal material mixed with a sufficient volume of binder to be fed into an injection mold 304 for molding and solidification, thereby producing an output having the configuration of armature 100. In another embodiment, the raw material 302 is a bar of metal material to be processed by a machine tool 304.

[0033] In this embodiment, the metallic material used for the raw material is a high-permeability metallic material that minimizes the remanence of the armature 100. The stress reduction provided by the recessed configuration of the end surface 114 at the second end 106 of the armature 100 allows such materials to be used in the manufacture of the armature 100 at a lower cost than materials used in prior art armatures, such as carbon steel. In this embodiment, the armature 100 is made of Fe3Si or other suitable ferritic soft magnetic silicon alloy materials capable of metal injection molding. Other embodiments envision other types of metallic materials capable of metal injection molding, processing, or otherwise manufacturing to form the armature 100 with the recessed end surface 114 according to this disclosure.

[0034] refer to Figure 5A method 400 for forming an armature 100 as a single, integral body using a metal injection molding process (such as by employing the metal injection molding process 300 discussed above). Method 400 includes an operation 402 that provides a raw material, such as raw material 302 for molding the armature 100. Method 400 also includes an operation 404 that forms the armature 100 using a metal injection molding process (such as by injecting raw material 302 into an injection mold 304 configured to mold the raw material 302 into a configuration of the armature 100 having a recessed end surface 114).

[0035] refer to Figure 6 A cross-sectional view illustrating an embodiment of a fuel injector 200 having an armature 100 associated with a valve 250 of the fuel injector 200 is shown. The fuel injector 200 generally includes an injector body 202, an elongated needle valve 204, a needle sleeve 206, a needle seal 208, an armature 100, and a plunger 112 extending through a channel 112 through the armature 100. The injector body 202 includes an upper chamber 214 and a lower chamber 216 for receiving multiple components therein, as would be conceived by those skilled in the art using the benefits and insights of this disclosure.

[0036] The armature 100 is configured to move vertically within the injector body 202 to facilitate the opening and closing of the valve 250 of the fuel injector 200. A stator assembly 222, including a solenoid 248, may be positioned directly above the armature 100 such that when the solenoid 248 is active, the armature 100 moves to an upward position. When the solenoid 248 is inactive (e.g., at the end of injection), the armature 100 moves to a downward position. An air gap (such as, for example, air gap 232) provides the distance between the stator assembly 222 and the armature 100. As discussed above, the armature 100 may be made of a highly permeable metallic material, thus reducing the likelihood of retaining residual magnetism. This facilitates demagnetization of the armature 100 from its magnetic connection with the solenoid 248 and reduces delay at the end of injection.

[0037] The upper chamber 214 of the injector body 202 houses the armature 100, plunger 212, armature spring 218, spring disc 220, and stator assembly 222. The lower chamber 216 houses the needle valve 204, needle sleeve 206, needle seal 208, pilot valve seat 224, and check ball 226. The upper chamber 214 provides a low-pressure environment for the fuel injector 200 relative to the high-pressure environment below the check ball 226. The stator assembly 222 is secured within the upper chamber 214 and held in place by a retainer 228. The bottom surface of the stator assembly 222 is precisely calibrated to the upper surface of the armature 100. At the other end of the armature 100 is a check ball retainer 230, which supports the armature 100 via abutment engagement.

[0038] The intermediate segment of plunger 212 includes an angled shoulder 213 disposed on the upper surface of armature 100, the shoulders forming an interconnection such that plunger 212 moves along with armature 100 in an upward direction. Armature spring 218 is biased against flange 108 of armature 100 and biased upward against armature 100 and plunger 212. Armature 100 includes a channel 112 that receives a shaft 215 through which plunger 212 passes. The outer diameter of shaft 215 is sized and configured to provide a tight fit or mating fit relative to the inner diameter of channel 112 while still allowing sliding movement of plunger 212. This tight fit / matting fit suppresses fuel leakage between the outer diameter of shaft 215 of plunger 212 and the inner diameter of channel 112 while allowing relative sliding movement.

[0039] A lower chamber 216, including an inner cavity, houses a needle valve 204, a needle sleeve 206, a needle seal 208, a pilot valve seat 224, and a check ball 226. This inner cavity also houses a needle spring 234 that biases the needle valve 204 in a downward direction and applies a closing spring force to the needle valve 204, thereby preventing fuel from leaving through the injector orifice 236. The needle seal 208 includes a control orifice 238 integrated within the needle seal 208 to receive fuel into the needle seal 208, with the proximal end of the needle valve 204 located within the needle seal 208. The needle seal 208 is positioned above the needle valve 204 and includes an end point terminating adjacent to the needle sleeve 206.

[0040] The lower end surface of the pilot valve seat 224 abuts against the top surface of the needle seal 208, while the upper end surface of the pilot valve seat 224 is positioned directly below the armature spring 218. The pilot valve seat 224 also includes a seat center channel 240 that extends longitudinally from the lower end of the pilot valve seat 224 toward the upper end.

[0041] The needle valve 204 moves longitudinally up and down within the injector body 202 to selectively initiate and deactivate fuel injection from the injector body 202. The distal end 217 of the needle valve 204 is located at the distal portion of the injector body 202, which defines a needle valve seat 242 that receives the tip 219 of the needle valve 204 between fuel injection events. For example, during a fuel injection event, the needle valve 204 rises from the needle seat 242, thereby injecting fuel into an engine cylinder (not shown).

[0042] The lower chamber 216 also includes a fuel inlet port 244 configured to supply fuel to the inner chamber of the lower chamber 216. A cross-drilled fluid passage 246 in the needle valve 204 further facilitates fuel flow through the lower chamber 216. A control port 238 directs fuel upward through the valve seat center passage 240. When the coil 221 is de-energized and the solenoid 248 is inactive, the check ball 226 seals against the pilot valve seat 224. The check ball 226 also functions as a movable valve member, allowing it to move out of the seal against the pilot valve seat 224. When the check ball 226 is seal against the pilot valve seat 224, fuel from the lower chamber 216 is prevented from entering the upper chamber 214. When fuel is supplied to the lower chamber 216 and the check ball 226 is seal against the pilot valve seat 224, the inner chamber of the lower chamber 216 becomes a high-pressure space. When the check ball 226 is used as a movable valve component and moves to disengage from the sealed engagement with the pilot valve seat 224, high-pressure fuel flows upward through the pilot valve seat 224 into the valve seat center passage 240 and into the inner cavity of the upper chamber 214.

[0043] The fuel injector 200 utilizes a needle valve 204 in a normally closed position. When the needle valve 204 is in the normally closed position, the coil 221 is de-energized and the solenoid 248 is inactive. The fuel injector 200 also includes a plunger return spring 251 that applies a downward spring force, causing the plunger 212 and armature 100 to exert a downward force on the check ball retainer 128, thereby securing the check ball 226 and maintaining it in a sealing engagement with the pilot valve seat 224. Pressurized fuel is continuously supplied to the interior of the lower chamber 216.

[0044] When coil 121 is de-energized, fuel from lower chamber 216 is prevented from entering upper chamber 214, thus creating high pressure within lower chamber 216. Due to the downward pressure of the fuel supply acting on needle valve 204, a greater downward hydraulic pressure pushes needle valve 204 downwards. Needle spring 234 is also located within lower chamber 216 and is compressed around the upper end of needle valve 204, such that when solenoid 248 is not activated, both the high-pressure fuel and the downward spring force on needle valve 204 hold needle valve 204 against needle valve seat 242. Holding needle valve 204 against needle valve seat 242 prevents high-pressure fuel from leaving fuel injector 200 through injector orifice 236.

[0045] In an example application of the armature 100 in the fuel injector 200, the flange 108 is located below the solenoid 248 and the coil 221. The plunger 212 includes a shaft portion disposed within and received by a channel 112 in the armature 100 to form an interconnection, such that the plunger 212 moves along with the armature 100 in an upward direction. An armature spring 218 is biased against the flange 108 to bias the armature 100 and the plunger 212 in an upward direction.

[0046] In an embodiment, armature 100 is configured to move axially within a fuel injector or other device as part of a valve assembly to facilitate the opening and closing of a valve (such as valve 250 of fuel injector 200). Figure 6 In the illustrated embodiment, a stator assembly 222 including a solenoid 248 may be positioned directly above the armature 100 such that when the solenoid 248 is active, the armature 100 moves to an upward position. When the solenoid 248 is inactive, the armature 100 moves to a downward position. An air gap (such as, for example, air gap 201) provides distance between the stator assembly 222 and the armature 100. An end surface 114 at the second end 106 of the armature 100 may be supported by a check ball retainer 230. An armature spring 218 may be biased against the flange 108 to bias the armature 100 and the plunger 212 in an upward direction.

[0047] Various aspects of this disclosure are contemplated. According to a first aspect, an armature is provided for use associated with the actuation of a valve. The armature includes a body extending along a longitudinal axis between a first end and an opposing second end. The body includes: a flange located at the first end; and a shaft extending from the flange. The shaft extends along the longitudinal axis from the flange to the second end of the body. The body also includes a channel extending along the longitudinal axis. The channel opens at both the first and second ends of the body. The second end of the body includes an end surface extending around the channel. The end surface has a first portion extending around the second portion. The first portion of the end surface is flat, and the second portion of the end surface is recessed from the first portion toward the first end of the body.

[0048] In this embodiment, the body is made of a metallic material. In this embodiment, the metallic material is a soft magnetic iron-silicon alloy. In this embodiment, the metallic material has undergone vacuum annealing. In this embodiment, the body is formed by metal injection molding.

[0049] In one embodiment, the first portion is orthogonal to the longitudinal axis. In another embodiment, the second portion is oriented at an angle to the first portion and also at an angle to the longitudinal axis. In another embodiment, the second portion is planar. In yet another embodiment, the second portion gradually narrows toward the first end at an angle of 0.1 to 1 degree relative to the first portion.

[0050] In one embodiment, the area of ​​the second portion is in the ratio of the area of ​​the first portion to a value of 4 to 7. In another embodiment, the ratio is between 5 and 6.

[0051] In one embodiment, the flange extends radially outward from the channel at the first end of the body, and the shaft extends from the flange along the channel.

[0052] In one embodiment, the channel includes: a first diameter adjacent to the second end of the body; a second diameter distributed along a large portion of the length of the channel between the first end and the second end of the body; and the first diameter of the channel is larger than the second diameter of the channel.

[0053] In one embodiment, the axis of the body includes an outer surface. The outer surface extends from the second end of the body to the flange. The outer surface has a stepped surface profile.

[0054] In another embodiment, the stepped surface profile of the outer surface of the shaft includes: a first shaft portion adjacent to the flange; and a second shaft portion adjacent to the first shaft portion. The first shaft portion has a first outer diameter, and the second shaft portion has a second outer diameter. The second outer diameter is smaller than the first outer diameter. The outer surface of the shaft also includes a third shaft portion adjacent to the second shaft portion. The third shaft portion extends from the second shaft portion to the second end of the body. The third shaft portion has a third outer diameter, which is smaller than the second outer diameter.

[0055] According to another aspect, a method of manufacturing an armature for use in conjunction with valve actuation includes forming a monolithic metal body using a metallic material and metal injection molding and / or bar forming processes. The monolithic metal body is formed to include: a flange located at a first end of the monolithic metal body; and a shaft extending from the flange along a longitudinal axis. The shaft extends to a second end of the monolithic metal body opposite the first end. A channel extending along the longitudinal axis opens at both the first and second ends of the monolithic metal body.

[0056] In one embodiment, the second end of the body includes an end surface that extends around the channel. The end surface has a first portion extending around the second portion. The first portion of the end surface is flat. The second portion of the end surface extends from the first portion toward the first end of the body into the channel.

[0057] In this embodiment, the metallic material is a soft magnetic iron-silicon alloy. In this embodiment, the monolithic metal body undergoes vacuum annealing after formation.

[0058] In one embodiment, the first portion is orthogonal to the longitudinal axis, and the second portion gradually narrows at a certain angle from the first portion toward the first end monolithic metal body.

[0059] While exemplary embodiments of the present disclosure have been illustrated and described in detail in the accompanying drawings and the foregoing description, these embodiments should be considered illustrative rather than restrictive. It should be understood that only certain exemplary embodiments have been shown and described, and protection is intended for all changes and modifications falling within the spirit of the claimed invention. It should be understood that while the use of words such as “preferred,” “ideally,” “preferred,” or “more preferred” in the foregoing description indicates that a feature so described may be more desirable, it may not be necessary, and embodiments lacking these features may be considered within the scope of the invention, as defined by the appended claims. When reading the claims, it is intended that when words such as “a,” “at least one,” or “at least a portion” are used, the claims are not intended to be limited to a single item unless expressly stated otherwise in the claims. When the terms “at least a portion” and / or “a portion” are used, the item may include a portion and / or the entire item unless the contrary is explicitly stated otherwise.

Claims

1. An armature for use in association with the actuation of a valve, the armature comprising: The body, extending along a longitudinal axis between a first end and an opposing second end, comprises: Flange, the flange being located at the first end; A shaft extending from the flange and along the longitudinal axis from the flange to the second end of the body; A channel extending along the longitudinal axis, the channel opening at a first end and a second end of the body, wherein the second end of the body includes an end surface extending around the channel, the end surface having a first portion extending around a second portion, wherein: The first portion of the end surface is flat; and The second portion of the end surface is recessed from the first portion toward the first end of the body.

2. The armature according to claim 1, wherein the body is made of a metallic material.

3. The armature according to claim 2, wherein the metallic material is a soft magnetic iron-silicon alloy.

4. The armature according to claim 2 or 3, wherein the metal material has undergone vacuum annealing.

5. The armature according to any one of claims 2 to 4, wherein the body is formed by metal injection molding.

6. The armature of claim 1, wherein the first portion of the end surface is orthogonal to the longitudinal axis of the body.

7. The armature of claim 1, wherein the second portion of the end surface is oriented at an oblique angle to the first portion of the end surface and at an oblique angle to the longitudinal axis of the body.

8. The armature of claim 7, wherein the second portion is planar.

9. The armature according to claim 7 or claim 8, wherein the second portion of the end surface gradually narrows toward the first end relative to the first portion of the end surface in the range of 0.1 degrees to 1 degree.

10. The armature of claim 1, wherein the ratio of the area of ​​the second portion of the end surface to the area of ​​the first portion of the end surface is 4 to 7.

11. The armature of claim 10, wherein the ratio is between 5 and 6.

12. The armature of claim 1, wherein the flange extends radially outward from the channel at the first end of the body, and the shaft extends from the flange along the channel.

13. The armature of claim 1, wherein the channel comprises: A first diameter, the first diameter being adjacent to the second end of the body; A second diameter is distributed along most of the length of the channel between the first end and the second end of the body; The first diameter of the channel is larger than the second diameter of the channel.

14. The armature according to claim 1, wherein: The shaft of the body includes an outer surface; The outer surface extends from the second end of the body to the flange; and The outer surface has a stepped surface profile.

15. The armature of claim 14, wherein the stepped surface profile of the outer surface of the shaft comprises: A first shaft portion, the first shaft portion being adjacent to the flange, the first shaft portion having a first outer diameter; A second shaft portion is adjacent to the first shaft portion, and the second shaft portion has a second outer diameter, wherein the second outer diameter is smaller than the first outer diameter; and A third axial portion, adjacent to the second axial portion, extending from the second axial portion to the second end of the body, the third axial portion having a third outer diameter smaller than the second outer diameter.

16. A method of manufacturing an armature for use in association with the actuation of a valve, the method comprising: A monolithic metal body is formed using metal materials and metal injection molding and / or bar processing techniques, the monolithic metal body comprising: a flange located at a first end of the monolithic metal body; a shaft extending from the flange along a longitudinal axis to a second end of the monolithic metal body opposite to the first end; and a channel extending along the longitudinal axis and opening at both the first and second ends of the monolithic metal body.

17. The method of claim 16, wherein the second end of the body includes an end surface extending around the channel, the end surface having a first portion extending around the second portion, wherein: The first portion of the end surface is flat; and The second portion of the end surface extends from the first portion toward the first end of the body to the channel.

18. The method according to claim 16 or claim 17, wherein the metallic material is a soft magnetic iron-silicon alloy.

19. The method according to any one of claims 16 to 18, wherein the monolithic metal body is subjected to vacuum annealing after formation.

20. The method according to any one of claims 16 to 19, wherein the first portion of the end surface is orthogonal to the longitudinal axis of the shaft, and the second portion of the end surface gradually narrows at an angle from the first portion of the end surface toward the first end of the monolithic metal body.

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