A water inlet solenoid valve and its implementation method

Abstract

This invention discloses a water inlet solenoid valve and its implementation method. The water inlet solenoid valve implementation method of this invention includes: winding a coil winding with a number of turns D that is lower than the standard number of turns B of the coil winding on a coil frame; then assembling the coil frame with the coil winding of the number of turns D with other components of the water inlet solenoid valve; by reducing the current flowing through the coil winding of the number of turns D during the start-up of the water inlet solenoid valve, providing a current adapted to the resistance value of the coil winding of the number of turns D, so as to prevent the temperature rise caused by the reduction in the resistance value of the coil winding due to the reduction in the number of turns of the coil winding.

Description

[0001] This invention is a divisional application of application number 201910485701.1 filed on June 5, 2019, entitled "A water inlet solenoid valve and its implementation method". Technical Field

[0002] This invention relates to the field of water inlet solenoid valve technology, and in particular to a water inlet solenoid valve and its implementation method that reduces the number of coil winding turns while ensuring normal start-up of the water inlet solenoid valve. Background Technology

[0003] Currently, inlet valves are mainly used in washing machines, dishwashers, coffee machines, ice makers, etc., and come in single-valve, double-valve, and triple-valve forms.

[0004] In automatic washing machines, the inlet solenoid valve controls the water supply. Because the water is under pressure during operation, it can be designed as a pilot-operated solenoid valve without a stuffing box. This is a commonly used structure, mainly composed of two parts: an upper pilot valve and a lower main valve.

[0005] When the winding is not energized, the movable iron core falls due to its own weight and the reaction force of the return spring, closing the flow hole of the main valve plug. This prevents water entering the upper cavity of the plug from the balance hole from leaking out. Because the effective pressure-bearing areas on the upper and lower surfaces of the plug diaphragm are different, a pressure difference is created, pressing the diaphragm against the main valve seat, thus closing the valve. When the winding is energized, the electromagnetic attraction draws the movable iron core upward, and the water in the upper cavity of the plug leaks out through the flow hole to the valve outlet. Since the flow capacity of the flow hole is designed to be much greater than that of the balance hole, a sufficiently large pressure loss occurs in the balance hole, causing a sharp drop in pressure in the upper cavity of the plug. Meanwhile, the pressure in the lower cavity remains the same as the inlet pressure. This pressure difference between the upper and lower surfaces of the plug diaphragm causes it to expand upward, opening the valve and allowing water to flow.

[0006] One of the main problems with existing inlet solenoid valves is that the coil winding used to provide electromagnetic attraction has approximately 14,000 to 16,000 turns, with a wire diameter as small as 0.06 mm. Due to manufacturing limitations, the minimum diameter for aluminum enameled wire is 0.12 mm, and for copper-clad aluminum wire, it is 0.1 mm. Therefore, without changing the size of the inlet solenoid valve, it is impossible to use aluminum enameled wire or copper-clad aluminum wire to wind 14,000-16,000 turns; thus, only copper enameled wire can be used for the coil winding. This has prevented the cost of inlet solenoid valves from being reduced.

[0007] Furthermore, the weight of 14,000-16,000 turns of copper wire with a diameter of 0.06mm is approximately between 26.5g and 28g. Therefore, how to reduce the weight of the copper wire used and further reduce the manufacturing cost of the water inlet solenoid valve is also a technical problem that this invention needs to consider. Summary of the Invention

[0008] The purpose of this invention is to provide a water inlet solenoid valve to solve the technical problems of existing water inlet solenoid valves being unable to use aluminum wire and using too much copper wire.

[0009] According to a first aspect of the present invention, a water inlet solenoid valve is provided, the water inlet solenoid valve having a rated voltage range of 200V to 240V, the method comprising:

[0010] A coil winding with a number of turns D lower than the standard number of turns B is wound on a coil frame, and then the coil frame with the coil winding with the number of turns D is assembled with other components of the water inlet solenoid valve.

[0011] By reducing the current flowing through the coil winding with D turns during the start-up of the inlet solenoid valve, a current adapted to the resistance value of the coil winding with D turns is provided in order to prevent the temperature rise caused by the reduction in the coil winding resistance value due to the reduction in the number of turns of the coil winding.

[0012] Wherein, the standard number of turns B of the coil winding is 14,000 to 16,000 turns as required by conventional design, and the number of turns D that is lower than the standard number of turns B of the coil winding is between 0.54B and 0.65B.

[0013] Preferably, the current flowing through the coil winding with D turns is reduced by connecting a current-limiting element in series in the power supply circuit of the coil winding.

[0014] Preferably, the coil frame is provided with a first plug that is connected at one end to the live wire or neutral wire of the power supply, a second plug that is connected at one end to the neutral wire or live wire of the power supply and at the other end to the coil winding, and a third plug that is connected at one end to the coil winding; the current limiting element is installed between the other end of the first plug and the other end of the third plug.

[0015] Preferably, the wire diameter of the coil winding with the number of turns D is at least 0.01 mm smaller than that of the coil winding with the standard number of turns B; the number of turns D is 9000 turns; and the coil winding is a copper enameled wire winding.

[0016] According to a second aspect of the present invention, a water inlet solenoid valve is provided, the water inlet solenoid valve having a rated voltage range of 200V to 240V, the method comprising:

[0017] A coil winding with a number of turns D lower than the standard number of turns B is wound on a coil frame, and then the coil frame with the coil winding with the number of turns D is assembled with other components of the water inlet solenoid valve.

[0018] By reducing the starting voltage across the coil winding, a starting voltage adapted to the coil winding with D turns is provided; by reducing the current flowing through the coil winding with D turns during the start-up of the water inlet solenoid valve, a drive current adapted to the resistance value of the coil winding with D turns is provided, thereby preventing temperature rise caused by the reduction in the coil winding resistance value due to the reduction in the number of coil turns.

[0019] Wherein, the standard number of turns B of the coil winding is 14,000 to 16,000 turns as required by conventional design, and the number of turns D that is lower than the standard number of turns B of the coil winding is between 0.48B and 0.58B.

[0020] Preferably, by connecting a current-limiting element and a voltage-dividing element in series in the power supply circuit of the coil winding, the current flowing through the coil winding with the number of turns D is reduced and the starting voltage across the coil winding is lowered.

[0021] Preferably, the coil frame is provided with a first plug that is connected at one end to the live wire or neutral wire of the power supply, a second plug that is connected at one end to the neutral wire or live wire of the power supply and at the other end to the coil winding, and a third plug that is connected at one end to the coil winding; the current limiting element and the voltage dividing element are connected in series and installed between the other end of the first plug and the other end of the third plug.

[0022] Preferably, the wire diameter of the coil winding with the number of turns D is the same as that of the coil winding with the standard number of turns B; the number of turns D is 8000 turns; and the coil winding is a copper enameled wire winding.

[0023] According to a third aspect of the present invention, a water inlet solenoid valve is provided, the water inlet solenoid valve having a rated voltage range of 200V to 240V, the method comprising:

[0024] A coil winding with a number of turns D lower than the standard number of turns B is wound on a coil frame, and then the coil frame with the coil winding with the number of turns D is assembled with other components of the water inlet solenoid valve.

[0025] By reducing the starting voltage across the coil winding, a starting voltage adapted to the resistance value of the coil winding with the number of turns D is provided in order to prevent temperature rise caused by the reduction in the resistance value of the coil winding due to the reduction in the number of turns of the coil winding.

[0026] Wherein, the standard number of turns B of the coil winding is 14,000 to 16,000 turns as required by conventional design, and the number of turns D that is lower than the standard number of turns B of the coil winding is between 0.36B and 0.43B or between 0.42B and 0.51B.

[0027] Preferably, the starting voltage across the coil winding is reduced by connecting a voltage divider element in series in the power supply circuit of the coil winding.

[0028] Preferably, the coil frame is provided with a first plug that is connected at one end to the live wire or neutral wire of the power supply, a second plug that is connected at one end to the neutral wire or live wire of the power supply and at the other end to the coil winding, and a third plug that is connected at one end to the coil winding; the voltage divider element is installed between the other end of the first plug and the other end of the third plug.

[0029] Preferably, the coil winding wire diameter of the number of turns D is at least 0.04 mm to 0.06 mm larger than that of the coil winding wire of the standard number of turns B; the number of turns D is 6000-7000 turns; and the coil winding wire is aluminum enameled wire or copper-clad aluminum wire winding.

[0030] According to a fourth aspect of the present invention, a water inlet solenoid valve is provided, the water inlet solenoid valve having a rated voltage range of 100V to 127V, the method comprising:

[0031] A coil winding with a number of turns D lower than the standard number of turns B is wound on a coil frame, and then the coil frame with the coil winding with the number of turns D is assembled with other components of the water inlet solenoid valve.

[0032] By reducing the current flowing through the coil winding with D turns during the start-up of the inlet solenoid valve, a current adapted to the resistance value of the coil winding with D turns is provided in order to prevent the temperature rise caused by the reduction in the coil winding resistance value due to the reduction in the number of turns of the coil winding.

[0033] The standard number of turns B of the coil winding is 6700-7700 turns as required by conventional design, and the number of turns D that is lower than the standard number of turns B of the coil winding is between 0.51B and 0.96B.

[0034] Preferably, the current flowing through the coil winding with the number of turns D is reduced by connecting a current-limiting element in series in the power supply circuit of the coil winding; the number of turns D, which is lower than the standard number of turns B of the coil winding, is between 0.51B and 0.64B, and the wire diameter of the coil winding with the number of turns D is at least 0.01mm smaller than the wire diameter of the coil winding with the standard number of turns B; the coil winding is a copper enameled wire winding.

[0035] Preferably, the current flowing through the coil winding with the number of turns D is reduced by connecting a current-limiting element in series in the power supply circuit of the coil winding; the number of turns D, which is lower than the standard number of turns B of the coil winding, is between 0.56B and 0.72B, and the wire diameter of the coil winding with the number of turns D is at least 0.02mm smaller than the wire diameter of the coil winding with the standard number of turns B; the coil winding is a copper enameled wire winding.

[0036] Preferably, the current flowing through the coil winding with the number of turns D is reduced by connecting a current-limiting element in series in the power supply circuit of the coil winding; the number of turns D, which is lower than the standard number of turns B of the coil winding, is between 0.75B and 0.96B, and the wire diameter of the coil winding with the number of turns D is at least 0.01mm larger than the wire diameter of the coil winding with the standard number of turns B; the coil winding is a copper-clad aluminum or aluminum enameled wire winding.

[0037] Preferably, the coil frame is provided with a first plug that is connected at one end to the live wire or neutral wire of the power supply, a second plug that is connected at one end to the neutral wire or live wire of the power supply and at the other end to the coil winding, and a third plug that is connected at one end to the coil winding; the current limiting element is installed between the other end of the first plug and the other end of the third plug.

[0038] According to the first to fourth aspects described above, the step of assembling the coil frame with the coil winding of the number D turns with other components of the water inlet solenoid valve includes:

[0039] A coil assembly with a central hole is formed by mounting elements including inserts on a coil frame on which a coil winding is wound.

[0040] A stator assembly is formed by installing an upper magnetic inner sleeve and a lower magnetic inner sleeve in the center hole of the coil assembly, and fixing the magnetic yokes that connect the upper and lower magnetic inner sleeves to the outside of the coil assembly.

[0041] Based on the stator assembly, a stator assembly with a water-proof sleeve is produced by molding.

[0042] The assembly of the inlet solenoid valve is completed by assembling the stator assembly with the water-proof sleeve and the valve body assembly together.

[0043] Preferably, the coil frame has a magnetic inner sleeve positioning member in the central hole for positioning the upper magnetic inner sleeve and the lower magnetic inner sleeve, so that the upper magnetic inner sleeve and the lower magnetic inner sleeve maintain a predetermined distance in the central hole of the coil frame.

[0044] Preferably, the upper and lower ends of the coil frame are respectively provided with magnetic yoke positioning bosses for positioning the magnetic yoke, and the magnetic yoke has magnetic yoke positioning grooves; the magnetic yoke is embedded into the magnetic yoke positioning bosses through its magnetic yoke positioning grooves.

[0045] Preferably, the step of molding the stator assembly to form a stator assembly with a water-proof sleeve includes:

[0046] The stator assembly is formed by injecting plastic into a mold, encapsulating the coil windings, yoke, and electronic components with plastic, but exposing the inserts and the central holes of the coil frame containing the upper and lower magnetic inner sleeves.

[0047] A water-proof sleeve is injection molded into the coil frame of the encapsulated stator assembly, which contains an upper magnetic sleeve and a lower magnetic inner sleeve, by placing the encapsulated stator assembly into a mold and injecting plastic.

[0048] Preferably, the upper magnetic inner sleeve and the lower magnetic inner sleeve are cylindrical, and the cylinder walls are provided with radial through holes for gluing, and the inner surfaces are provided with axial grooves.

[0049] Preferably, the upper magnetic inner sleeve and the lower magnetic inner sleeve are cylindrical, and the cylindrical wall is provided with a radial through hole for gluing, and the inner surface is provided with an axial groove, which communicates with the radial through hole.

[0050] Preferably, by injecting plastic into the hole of the coil frame containing the upper and lower magnetic inner sleeves, the injected plastic used to form the water-proof sleeve flows along the axial groove into the radial through hole, forming the root of the water-proof sleeve for fixing the injection-molded water-proof sleeve.

[0051] Preferably, when injecting plastic into the stator assembly, the connecting part of the magnetic yoke that connects the upper magnetic inner sleeve and the lower magnetic inner sleeve is first pressed with a mold, and then plastic is injected into the other parts of the stator assembly except for the inserts.

[0052] Preferably, the step of assembling the coil frame with the coil winding of the number D turns with other components of the water inlet solenoid valve includes: installing a magnetic yoke on the coil assembly and then encapsulating it to form a encapsulated coil assembly with a magnetic yoke; using the upper magnetic inner sleeve and the lower magnetic inner sleeve placed together as inserts for injection molding to form a water-proof sleeve assembly; and assembling the encapsulated coil assembly with the magnetic yoke, the water-proof sleeve assembly, and the valve body assembly together to complete the assembly of the integrated water inlet solenoid valve.

[0053] Preferably, the step of assembling the coil frame with the coil winding of D turns and other components of the water inlet solenoid valve includes: installing inserts on the coil frame with the coil winding and then encapsulating it to form a plastic-encapsulated coil assembly without a magnetic yoke; using the upper magnetic inner sleeve and the lower magnetic inner sleeve placed together as inserts for injection molding to form a water-proof sleeve assembly; and assembling the plastic-encapsulated coil assembly without a magnetic yoke, the magnetic yoke, the water-proof sleeve assembly and the valve body assembly together to complete the assembly of the integrated water inlet solenoid valve.

[0054] Preferably, the step of assembling the coil frame with the coil winding of D turns and other components of the water inlet solenoid valve includes: forming a coil assembly by mounting the coil winding and inserts on the coil frame; injection molding an upper magnetic inner sleeve and a lower magnetic inner sleeve placed together as inserts to form a water-proof sleeve assembly; installing a magnetic yoke onto the coil assembly; inserting the water-proof sleeve assembly with the magnetic sleeve into the cavity of the coil assembly; and performing injection molding to form an integrated encapsulated stator assembly that encapsulates the coil assembly, the magnetic yoke, and the water-proof sleeve assembly; and assembling the integrated encapsulated stator assembly and the valve body assembly together to complete the assembly of the integrated water inlet solenoid valve.

[0055] According to a fifth aspect of the present invention, the present invention also provides an integrated water inlet solenoid valve implemented according to the above method.

[0056] Compared with the prior art, the beneficial technical effects of the present invention are: 1) it can save copper usage while ensuring the normal start-up of the water inlet solenoid valve; 2) it can use aluminum wire as the coil winding without changing the volume of the water inlet solenoid valve; 3) by injection molding a water-proof sleeve on the inner surface of the upper magnetic inner sleeve, the limiting member and the lower magnetic inner sleeve, the thickness of the water-proof sleeve can be greatly reduced, thereby improving the electromagnetic attraction force on the driving movable iron core.

[0057] The present invention will now be described in detail with reference to the accompanying drawings and embodiments, so as to further understand the content, features and technical effects of the present invention. Attached Figure Description

[0058] Figure 1 This is a circuit diagram of a winding series diode according to the first embodiment of the present invention;

[0059] Figure 2 This is a perspective view of the insert according to the first embodiment of the present invention;

[0060] Figure 3 This is a perspective view of the coil frame according to the first embodiment of the present invention;

[0061] Figure 4 This is a perspective view of the coil frame for inserting the insert according to the first embodiment of the present invention;

[0062] Figure 5 This is a perspective view of the coil assembly according to the first embodiment of the present invention;

[0063] Figure 6 This is a perspective view of the encapsulated coil assembly according to the first embodiment of the present invention;

[0064] Figure 7 This is a cross-sectional view of the encapsulated coil assembly according to the first embodiment of the present invention;

[0065] Figure 8This is a three-dimensional assembly diagram of the water inlet valve according to the first embodiment of the present invention;

[0066] Figure 9 This is a perspective view of the water inlet valve according to the first embodiment of the present invention;

[0067] Figure 10 This is a cross-sectional view of the water inlet valve in the closed state according to the first embodiment of the present invention. The magnetic yoke is not shown in the figure.

[0068] Figure 11 This is a circuit diagram of the winding series resistor according to the second embodiment of the present invention;

[0069] Figure 12 This is a perspective view of the insert according to the second embodiment of the present invention;

[0070] Figure 13 This is a perspective view of the coil frame according to the second embodiment of the present invention;

[0071] Figure 14 This is a cross-sectional view of the coil frame according to the second embodiment of the present invention;

[0072] Figure 15 This is a perspective view of the coil frame for inserting the insert according to the second embodiment of the present invention;

[0073] Figure 16 This is a perspective view of a coil frame with windings according to the second embodiment of the present invention;

[0074] Figure 17 This is a three-dimensional assembly diagram of the coil assembly according to the second embodiment of the present invention;

[0075] Figure 18 This is a perspective view of the coil assembly according to the second embodiment of the present invention;

[0076] Figure 19 This is a perspective view of the encapsulated coil assembly according to the second embodiment of the present invention;

[0077] Figure 20 This is a cross-sectional view of the encapsulated coil assembly according to the second embodiment of the present invention;

[0078] Figure 21 This is a perspective view of the encapsulated coil assembly with a water-proof sleeve according to the second embodiment of the present invention;

[0079] Figure 22 This is a cross-sectional view of the encapsulated coil assembly with a water-proof sleeve according to the second embodiment of the present invention;

[0080] Figure 23 This is a three-dimensional assembly diagram of the water inlet valve according to the second embodiment of the present invention;

[0081] Figure 24 This is a perspective view of the water inlet valve according to the second embodiment of the present invention;

[0082] Figure 25 This is a cross-sectional view of the water inlet valve in the closed state according to the second embodiment of the present invention;

[0083] Figure 26 This is a front view of the magnetic inner sleeve according to the second embodiment of the present invention;

[0084] Figure 27 This is a cross-sectional view of the magnetic inner sleeve AA according to the second embodiment of the present invention;

[0085] Figure 28 This is a cross-sectional view of the magnetic inner sleeve BB according to the second embodiment of the present invention;

[0086] Figure 29 This is a perspective view of the magnetically conductive inner sleeve according to the second embodiment of the present invention;

[0087] Figure 30 This is a circuit diagram of the winding series resistor and diode according to the third embodiment of the present invention;

[0088] Figure 31 This is a three-dimensional assembly diagram of the water inlet valve according to the fourth embodiment of the present invention;

[0089] Figure 32 This is a three-dimensional assembly schematic diagram of the water inlet valve according to the fifth embodiment of the present invention;

[0090] Figure 33 This is a three-dimensional assembly diagram of the water inlet valve according to the sixth embodiment of the present invention;

[0091] Figure 34 This is a schematic diagram of the first technical solution of a water inlet solenoid valve implementation method according to the present invention;

[0092] Figure 35 This is a schematic diagram of the second technical solution of a water inlet solenoid valve implementation method according to the present invention;

[0093] Figure 36 This is a schematic diagram of the third technical solution of the water inlet solenoid valve implementation method of the present invention.

[0094] Explanation of reference numerals in the attached drawings: Coil frame - 104; Magnetic sleeve limiting component - 106; Insert - 107; First insert - 107-1; Second insert - 107-2; Third insert - 107-3; Electronic component - 108; Coil winding - 109; Magnetic yoke positioning boss - 110; Magnetic yoke - 111; Magnetic yoke positioning groove - 112; Upper magnetic inner sleeve 113; Lower magnetic inner sleeve 114; Radial glue passage hole - 115; Plastic sealing layer - 116; Waterproof sleeve - 117; Waterproof sleeve base - 118; Waterproof sleeve inner cavity - 119; Welding cap - 120; Axial inner groove 122; Joint seam 123; Wire end welding post 125; Wire tail welding post 126; Coil frame end face - 127; Return spring - 200; Movable iron core - 201; Rubber flow hole plug - 202; Plastic valve plug - 203; Rubber valve plug - 204; Valve body 205; Mounting bracket - 206; Pressure reducing ring 207; Plastic gasket 208; Filter screen assembly - 209; Flow hole - 210; Upper chamber of valve plug - 211; Lower chamber of valve plug - 212; Balance hole - 213; Inlet - 215; Outlet - 216; Interface 217. Detailed Implementation

[0095] The number of turns (B) in the coil winding of existing water inlet solenoid valves is a standard number of turns specified to provide electromagnetic attraction. This standard number of turns (B) is typically between 14,000 and 16,000 turns, and this has become common knowledge or a technical specification. Through in-depth research on water inlet solenoid valves, the inventors discovered that the electromagnetic attraction provided by a coil winding with a standard number of turns is actually far greater than the electromagnetic attraction required to open the water inlet solenoid valve. Furthermore, they found that for a water inlet solenoid valve with a rated voltage of 220V, the relationship between the minimum starting voltage of the water inlet solenoid valve and the number of turns in the coil winding is shown in Table 1. When the number of turns in the coil winding is between 15,000 and 6,000, the minimum starting voltage of the water inlet solenoid valve continuously decreases because the coil winding resistance decreases as the number of turns decreases. However, between 5,000 and 2,000 turns, the minimum starting voltage of the water inlet solenoid valve continuously rises again, and the heat generated after the coil is energized will increase sharply. This is an abnormal phenomenon and is undesirable.

[0096] Since the standard voltage of industrial frequency AC is 220 volts, it is possible to achieve a coil winding with fewer turns by reducing the minimum starting voltage on the coil winding. By reducing the number of coil winding turns, it is possible to use aluminum wire with a larger diameter without changing the size of the water inlet solenoid valve; it is also possible to reduce the amount of copper used and lower manufacturing costs by reducing the number of coil winding turns.

[0097] Table 1

[0098]

[0099]

[0100] Figure 31 This invention illustrates a first technical solution for implementing a water inlet solenoid valve based on the inventor's above-mentioned research. The water inlet solenoid valve has a rated voltage of 220V. The first technical solution includes:

[0101] A coil winding 109 with a number of turns D lower than the standard number of turns B of the coil winding is wound on the coil frame 104, and then the coil frame with the coil winding of the number of turns D is assembled with the other components of the water inlet solenoid valve.

[0102] By reducing the current flowing through the coil winding with D turns during the start-up of the inlet solenoid valve, a current adapted to the resistance value of the coil winding with D turns is provided in order to prevent temperature rise caused by the reduction in the resistance value of the coil winding due to the reduction in the number of turns.

[0103] Wherein, the standard number of turns B of the coil winding is 14,000-16,000 turns as required by the technical specifications, and the number of turns D that is lower than the standard number of turns B of the coil winding is 0.6B.

[0104] On the other hand, considering that the rated voltage of AC power used in some countries or regions may be higher or lower than 220V, that is, AC power with a rated voltage between 200V and 240V is used, the first technical solution is suitable for a rated voltage of 200V-240V with the number of turns D between 0.54B and 0.65B (i.e., 0.54B≤D≤0.65B).

[0105] In the first technical solution of the present invention, the current flowing through the coil winding with the number of turns D is reduced by connecting a current-limiting element (such as a diode) in series in the power supply circuit of the coil winding 109.

[0106] In the first technical solution of the present invention, the coil frame 104 is provided with a first plug 107-1, one end of which is connected to the live wire of the power supply; a second plug 107-2, one end of which is connected to the neutral wire of the power supply and the other end of which is connected to the coil winding; and a third plug 107-3, one end of which is connected to the coil winding; a current limiting element is installed between the other end of the first plug 107-1 and the other end of the third plug 107-3. (See also...) Figure 2 , Figure 4 , Figure 12 .

[0107] In the first technical solution of the present invention, the wire diameter of the coil winding with the number of turns D is at least 0.01 mm lower than that of the coil winding with the standard number of turns B; the number of turns D is 9000 turns; and the coil winding is a copper enameled wire winding.

[0108] Figure 32This invention discloses a second technical solution for implementing a water inlet solenoid valve, wherein the rated voltage of the water inlet solenoid valve is 220V, and the technical solution includes:

[0109] A coil winding 109 with a number of turns D lower than the standard number of turns B is wound on a coil frame 104, and then the coil frame 104 with the coil winding 109 wound with the number of turns D is assembled with other components of the water inlet solenoid valve.

[0110] By reducing the current flowing through the coil winding with D turns during the start-up of the inlet solenoid valve and lowering the starting voltage across the coil winding, a current and a starting voltage adapted to the resistance value of the coil winding 109 with D turns are provided to prevent temperature rise caused by the reduction in the resistance value of the coil winding due to the reduction in the number of turns.

[0111] Wherein, the standard number of turns B of the coil winding is 14,000-16,000 turns as required by the technical specifications, and the number of turns D that is lower than the standard number of turns B of the coil winding is 0.533B.

[0112] On the other hand, considering that the rated voltage of AC power used in some countries or regions may be higher or lower than 220V, that is, AC power with a rated voltage between 200V and 240V is used, the second technical solution is suitable for AC power with a rated voltage of 200V-240V and a number of turns D between 0.48B and 0.58B (i.e., 0.48B≤D≤0.58B).

[0113] In the second technical solution of the present invention, by connecting a current-limiting element (such as a diode) and a voltage-dividing element (such as a resistor) in series in the power supply circuit of the coil winding, the current flowing through the coil winding with the number of turns D during the start-up of the water inlet solenoid valve is reduced and the starting voltage at both ends of the coil winding is lowered.

[0114] In the second technical solution of the present invention, the coil frame is provided with a first plug 107-1 whose one end is connected to the live wire of the power supply, a second plug 107-2 whose one end is connected to the neutral wire of the power supply and whose other end is connected to the coil winding, and a third plug whose one end is connected to the coil winding; the current limiting element and the voltage dividing element are connected in series and installed between the other end of the first plug and the other end of the third plug.

[0115] In the second technical solution of the present invention, the wire diameter of the coil winding with number of turns D is the same as that of the coil winding with standard number of turns B; the number of turns D is 8000 turns; the coil winding is a copper enameled wire winding.

[0116] Figure 33 This invention discloses a third technical solution for implementing a water inlet solenoid valve, wherein the rated voltage of the water inlet solenoid valve is 220V, and the third technical solution includes:

[0117] A coil winding 109 with a number of turns D lower than the standard number of turns B of the coil winding is wound on the coil frame 104, and then the coil frame with the coil winding of the number of turns D is assembled with the other components of the water inlet solenoid valve.

[0118] By reducing the starting voltage across the coil winding, a starting voltage adapted to the resistance value of the coil winding with D turns is provided in order to prevent temperature rise caused by the reduction in resistance value due to the reduction in the number of turns of the coil winding.

[0119] Wherein, the standard number of turns B of the coil winding is 14,000 to 16,000 turns as required by the technical specifications, and the number of turns D below the standard number of turns B of the coil winding is between 0.4B and 0.466B.

[0120] On the other hand, considering that the rated voltage of AC used in some countries or regions may be higher or lower than 220V, that is, AC with a rated voltage between 200V and 240V is used, the third technical solution is suitable for a rated voltage of 200V-240V with the number of turns D between 0.36B and 0.43B (corresponding to 0.1mm copper-clad aluminum wire) or between 0.42B and 0.51B (corresponding to 0.12mm aluminum wire).

[0121] In the third technical solution of the present invention, by connecting a voltage divider element in series in the power supply circuit of the coil winding, the driving current of the coil winding with the number of turns D used to drive the start of the water inlet solenoid valve is reduced and the starting voltage at both ends of the coil winding is lowered.

[0122] In the third technical solution of the present invention, the coil frame 104 is provided with a first plug 107-1, one end of which is connected to the live wire or neutral wire of the power supply; a second plug 107-2, one end of which is connected to the neutral wire or live wire of the power supply and the other end of which is connected to the coil winding; and a third plug 107-3, one end of which is connected to the coil winding; the voltage divider element is installed between the other end of the first plug 107-1 and the other end of the third plug 107-3.

[0123] In the third technical solution of the present invention, the wire diameter of the coil winding with the number of turns D is at least 0.04 mm to 0.06 mm larger than that of the coil winding with the standard number of turns B; the number of turns D is 6000-7000 turns; and the coil winding wire is aluminum enameled wire or copper-clad aluminum wire winding.

[0124] It should be noted that the aforementioned current limiting components and / or voltage dividing components can also be installed in the power supply module or control board.

[0125] It should be noted that the current limiting element mentioned above is not limited to diodes, but can also be any unidirectional conducting element.

[0126] It should be noted that the electromagnetic attraction force of the inlet solenoid valve is related to the number of turns in the winding and the current. To maintain the same electromagnetic attraction force, reducing the number of turns inevitably increases the current, which leads to overheating and may even cause the inlet valve to burn out. Therefore, the contribution of this invention lies in the discovery that the electromagnetic attraction force of existing inlet solenoid valves far exceeds the required electromagnetic attraction force. This can be addressed by reducing the number of turns in the coil winding and by reducing the current flowing through the coil winding, thereby reducing the electromagnetic attraction force and achieving reliable start-up of the inlet solenoid valve.

[0127] In summary, the first technical solution of this invention reduces the winding weight by reducing the winding wire diameter and the number of winding turns, and the coil winding is connected in series with a diode (see...). Figure 1 For the same length, a smaller wire diameter results in a higher resistance. Replacing a large wire diameter winding with a smaller diameter one significantly reduces the number of turns, drastically decreasing the coil winding resistance, increasing the current, and consequently, increasing the temperature rise. Therefore, by connecting a diode in series with the winding and using chopping to reduce the current, the temperature rise is ultimately reduced.

[0128] It should be noted that the reduced number of turns in the coil winding leads to a decrease in the coil winding resistance, which in turn increases the current flowing through the coil winding. Therefore, the purpose of connecting a diode in series with the coil winding is to reduce the current through chopping, thereby reducing the temperature rise.

[0129] If the standard number of turns B is used, there is no need to connect a diode in series, because the operating temperature of the coil winding with the standard number of turns B is suitable and there is no need to lower the operating temperature.

[0130] The second technical solution of this invention reduces the winding weight by reducing the number of winding turns, using a winding series resistor and diode, see [link to related documentation]. Figure 30 The copper wire diameter remains unchanged, but the number of turns is significantly reduced, decreasing the amount of copper wire used. This reduces the winding resistance, increases the current, and raises the temperature rise. The voltage across the winding is reduced by resistor division, and the average current through the winding is reduced by diode chopping, ultimately reducing the temperature rise. The specific design is shown in configuration scheme two.

[0131] The third technical solution of this invention uses aluminum wire windings with a larger wire diameter and fewer turns, and the windings are connected in series with a resistor, see [link to relevant documentation]. Figure 11 For the same length, the impedance of 0.06mm copper wire is equivalent to that of 0.07mm aluminum wire. However, current aluminum wire manufacturing processes can only achieve a minimum diameter of 0.12mm. Therefore, using aluminum wire with a larger diameter instead of copper wire reduces the winding impedance, increases the current, and increases the temperature rise. Connecting a resistor in series with the winding reduces the current through voltage division, ultimately reducing the temperature rise.

[0132] Table 2 provides optimal examples of diodes, resistors, enameled wire types, and number of turns for the three technical solutions described above when the rated voltage is 220V. It should be noted that those skilled in the art can make more or less changes to the values ​​described in Table 2 according to actual conditions.

[0133] Table 2

[0134] diode resistance Enamelled wire type Number of turns Winding weight Existing technical solutions none none 0.06mm copper wire 15000 26.5-28g Solution 1 of the present invention have none 0.05mm copper wire 9000 8.1g Scheme 2 of the present invention have 1000Ω 0.06mm copper wire 8000 9.7g Scheme 3 of the present invention none 2000Ω 0.1mm copper-clad aluminum wire 6000 10g Scheme 3 of the present invention none 2000Ω 0.12mm aluminum wire 7000 15g

[0135] On the other hand, the inventors also discovered that for a water inlet solenoid valve with a rated voltage of 110V, the minimum starting voltage is approximately 96V, and the temperature rise is within 110K. Therefore, the winding weight can also be reduced by decreasing the winding wire diameter and the number of winding turns, with a diode connected in series with the winding.

[0136] Therefore, for a water inlet solenoid valve with a rated voltage of 110V, the implementation method of the water inlet solenoid valve of the present invention also has the following fourth to sixth technical solutions.

[0137] In the fourth to sixth technical solutions of the present invention, a coil winding with a number of turns D lower than the standard number of turns B of the coil winding is first wound on a coil frame, and then the coil frame with the coil winding with the number of turns D is assembled with other components of the water inlet solenoid valve; by reducing the current flowing through the coil winding with the number of turns D during the start-up of the water inlet solenoid valve, a current adapted to the resistance value of the coil winding with the number of turns D is provided, so as to prevent the temperature rise caused by the reduction in the resistance value of the coil winding due to the reduction in the number of turns of the coil winding.

[0138] And can be according to Figure 1 The circuit shown connects a current-limiting element in series with the power supply circuit of the coil winding to reduce the current flowing through the coil winding with D turns. In specific implementations, it can be done according to... Figure 2 As shown, the coil frame is provided with a first plug that is connected at one end to the live or neutral wire of the power supply, a second plug that is connected at one end to the neutral or live wire of the power supply and at the other end to the coil winding, and a third plug that is connected at one end to the coil winding; the current limiting element is installed between the other end of the first plug and the other end of the third plug.

[0139] For the fourth technical solution, the standard number of turns B of the coil winding is 6700-7700 turns as required by conventional design, and the number of turns D below the standard number of turns B is 0.56B. The wire diameter of the coil winding with the number of turns D is at least 0.01mm smaller than the wire diameter of the coil winding with the standard number of turns B; the number of turns D is 4000 turns; and the coil winding is a copper enameled wire winding.

[0140] On the other hand, considering that the rated voltage of AC used in some countries or regions may be higher or lower than 110V, that is, AC with a rated voltage between 100V and 127V is used, the fourth technical solution is suitable for a rated voltage of 100V-127V with the number of turns D between 0.51B and 0.64B (i.e., 0.51B≤D≤0.64B).

[0141] For the fifth technical solution, the standard number of turns B of the coil winding is 6700-7700 turns as required by conventional design, and the number of turns D below the standard number of turns B is 0.63B. The wire diameter of the coil winding with the number of turns D is at least 0.02mm smaller than the wire diameter of the coil winding with the standard number of turns B; the number of turns D is 4500 turns; and the coil winding is a copper enameled wire winding.

[0142] On the other hand, considering that the rated voltage of AC power used in some countries or regions may be higher or lower than 110V, that is, AC power with a rated voltage between 100V and 127V is used, the fifth technical solution is adapted to the number of turns D of 100V-127V rated voltage between 0.56B and 0.72B (i.e., 0.56B≤D≤0.72B).

[0143] For the sixth technical solution, the standard number of turns B of the coil winding is 6700-7700 turns as required by conventional design, and the number of turns D below the standard number of turns B is 0.83B. The coil winding is a copper-clad aluminum or aluminum enameled wire winding, and the wire diameter of the coil winding with the number of turns D is at least 0.01mm larger than the wire diameter of the coil winding with the standard number of turns B; the number of turns D is 6012 turns.

[0144] On the other hand, considering that the rated voltage of AC power used in some countries or regions may be higher or lower than 110V, that is, AC power with a rated voltage between 100V and 127V is used, the sixth technical solution is adapted to the number of turns D of 100V-127V rated voltage between 0.75B and 0.96B (i.e., 0.75B≤D≤0.96B).

[0145] The specific design of the inlet solenoid valve of the present invention with a rated voltage of 110V is shown in Table 3 below.

[0146] Table 3

[0147]

[0148]

[0149] Furthermore, the present invention can also improve the manufacturing method of the water inlet solenoid valve to increase the force of the electromagnetic attraction generated by the coil winding on the movable iron core, because the start-up of the water inlet solenoid valve is actually achieved by the force of the electromagnetic attraction generated by the coil winding on the movable iron core.

[0150] In the first to sixth technical solutions described above, the step of assembling the coil frame 104 of the coil winding 109 with the number of turns D with other components of the water inlet solenoid valve includes:

[0151] A coil assembly with a central hole is formed by mounting elements including inserts and electronic components (such as diodes and / or resistors) on the coil holder 104 on which the coil winding is wound. See [reference needed] Figures 13-16 ;

[0152] A stator assembly is formed by installing a magnetic sleeve 113 and a lower magnetic sleeve 114 through the central hole on the coil assembly, and fixing the magnetic yoke 111, which connects the upper magnetic sleeve 113 and the lower magnetic sleeve 114 respectively, to the outside of the coil assembly. See [link to documentation]. Figure 17-18 ;

[0153] Based on the aforementioned stator assembly, a stator assembly with a water-proof sleeve 117 is manufactured by molding. See [link to documentation]. Figures 19-22 ;

[0154] The assembly of the inlet solenoid valve is completed by assembling the stator assembly with the water-proof sleeve 117 and the valve body assembly together. See [link to documentation]. Figures 23-25 .

[0155] See Figure 23 The valve body assembly of the inlet solenoid valve includes: a return spring 200 and a movable iron core 201 installed in the central hole of the stator assembly 100 with a water-proof sleeve; a rubber flow hole plug 202; a valve plug 203; a valve plug rubber 204; a valve body 205; a mounting bracket 207; a pressure reducing ring 207; a rubber gasket 208; a filter screen assembly 209, etc. These components are all existing components of inlet solenoid valves, and their connection relationships are basically the same as those of existing technologies.

[0156] In addition, the water inlet solenoid valve of the present invention may also include a welded cap 120 inserted into the upper end of the central hole of the stator assembly 100 with a water-proof sleeve.

[0157] Figures 13-16 The specific process of forming the coil assembly with a central hole according to the present invention is shown. First, a coil frame 104 with a central hole is manufactured. Magnetic yoke positioning bosses 110 for positioning the magnetic yoke are machined on both end faces of the coil frame. See [link to documentation]. Figure 13 This invention can further reduce the wall thickness of the cylindrical portion of the coil frame to 0.6 mm. Specifically, a magnetic sleeve positioning element 106, such as a positioning ring or positioning rib, is installed within the central hole of the coil frame 104 to position the upper magnetic sleeve 113 and the lower magnetic sleeve 114, thereby maintaining a predetermined distance between the upper magnetic sleeve 113 and the lower magnetic sleeve 114 within the central hole of the coil frame 104. (See [link to previous section]). Figure 4Then, install the insert 107 on the upper surface of the coil holder 104, see [reference]. Figure 15 ; winding the coil 109 and welding the electronic components 108, thereby forming Figure 16 The coil assembly is shown. It should be noted that there is no restriction on the order of winding the coil winding 109, installing the electronic components 108, and installing the inserts 107; any component can be installed first or last.

[0158] Figures 17-18 The process of constructing the stator assembly of the present invention is shown. A magnetic sleeve 113 and a lower magnetic sleeve 114 are installed in the central hole of the coil assembly. A magnetic sleeve positioning ring 106 inside the central hole of the coil frame 104 defines the upper magnetic sleeve 113 and the lower magnetic sleeve 114 in a position where they can contact the magnetic yoke 111. Then, the magnetic yoke positioning groove 112 of the magnetic yoke 111 engages with the magnetic yoke positioning bosses 110 on the upper and lower end faces of the coil frame 104, so that the magnetic yoke 111 is positioned on the coil frame 104 on one hand, and in close contact with the upper magnetic sleeve 113 and the lower magnetic sleeve 114 on the other hand, forming an electrical connection, thereby forming... Figure 18 The stator assembly shown.

[0159] Figures 21-22 The process of forming a stator assembly with a water-proof sleeve according to the present invention is illustrated. The steps of forming a stator assembly with a water-proof sleeve by molding, based on the stator assembly or as an insert, include:

[0160] By Figure 19 The stator assembly shown is placed into a mold and plastic is injected in one go. The plastic wraps around the coil winding 109, the magnetic yoke 111, and the electronic components 108, but exposes the insert 107 and the central hole of the coil frame containing the upper magnetic sleeve 113 and the lower magnetic sleeve 114, forming a shape as shown. Figure 9 The plastic-encapsulated stator assembly shown;

[0161] By placing the encapsulated stator assembly 101 into a mold and injecting plastic a second time, a water-proof sleeve 117 is injection molded into the central hole of the coil frame containing the upper and lower magnetic sleeves of the encapsulated stator assembly 102, thereby producing... Figure 20 The stator assembly with a water-proof sleeve is shown.

[0162] Figure 22The structure of a stator assembly 100 with a water-resistant sleeve is shown, wherein the magnetic yoke 111 is tightly fixed to the coil assembly 103 by a molding compound 116, and a portion of the water-resistant sleeve 117 is injection-molded onto the inner walls of the upper magnetic sleeve 113 and the lower magnetic sleeve 114 of the coil frame, thereby injection-molding a water-resistant sleeve 117 with a thickness of approximately 0.6 mm into the central hole of the coil frame. In other words, the present invention reduces the thickness of the water-resistant sleeve 117 through an injection molding process. Compared to the 1.7 mm thick water-resistant sleeve of the prior art, the present invention can significantly reduce the gap between the movable iron core 201 and the magnetic sleeve, increasing the electromagnetic force exerted on the movable iron core 201. Therefore, the present invention is beneficial for reducing the electromagnetic attraction generated by the coil winding, and thus beneficial for reducing the number of turns in the coil winding.

[0163] In addition, during the secondary injection molding of plastic, a base 118 with an externally threaded water-proof sleeve is also injection molded (see...). Figure 21 This allows the stator assembly 100 with the water-proof sleeve to be screwed onto the valve body 205 with internal threads when assembling the inlet solenoid valve.

[0164] Figures 26-29 The structure of the upper and lower magnetic sleeves of the present invention is shown. The upper magnetic sleeve 113 and the lower magnetic sleeve 114 of the present invention are cylindrical, and the cylindrical wall is provided with a water-proof sleeve attachment structure for attaching the injection-molded water-proof sleeve to the inner surface of the upper magnetic sleeve 113 and the lower magnetic sleeve 114. The attachment structure includes: a radial through hole 115 for glue application, and an axial groove 122 provided on the inner surface (for facilitating the flow of hot-melt plastic during injection molding). The axial groove 122 communicates with the radial through hole 115. By injecting plastic into the hole in the coil frame containing the upper and lower magnetic sleeves, the injected plastic used to form the water-proof sleeve flows along the groove 122 of the upper and lower magnetic sleeves into the magnetic sleeve through hole 115, forming the root of the injection-molded water-proof sleeve 117 for positioning, so that the water-proof sleeve 117 is firmly fixed on the upper magnetic sleeve 113 and the lower magnetic sleeve 114, which have been positioned by the magnetic sleeve positioning ring 106. Both the upper and lower cylindrical magnetic sleeves are made of rolled flat material, thus possessing... Figure 28 The magnetic sleeve joint 123 is shown. The attachment structure may also include a circumferential groove (not shown) on the inner surface.

[0165] Furthermore, the present invention also provides an integrated inlet solenoid valve implemented by the above method, see [link to related document]. Figure 23-25 .

[0166] The following three embodiments illustrate the manufacturing process of the water inlet solenoid valve of the present invention. It should be noted that the following embodiments are merely examples and are not intended to limit the present invention.

[0167] Example 1:

[0168] Compared with the prior art, this embodiment reduces the amount of copper wire used, and the coil winding is connected in series with the diode (e.g., Figure 1 As shown). Figure 5 and Figure 6 As shown, the coil assembly includes a coil winding 109, a coil frame 104, inserts 107-1, 107-2, 107-3, and electronic components (such as diodes) 108. Figure 3 The coil frame is a cylindrical plastic component with an end face at one end. The winding is wound around the cylindrical coil frame, with the two ends of the winding forming the lead start and lead tail, respectively. For example... Figures 2 to 4 Inserts 107-1, 107-2, and 107-3 are insulated from each other and inserted into the end face of the coil frame. Inserts 107-1 and 107-3 are used for power supply connection, and are arranged parallel to each other, with the length of insert 107-1 greater than that of insert 107-3. Insert 107-2 is positioned behind insert 107-3 in the same direction. Insert 107-2 has a wire tail welding post, which connects to the tail end of the winding lead. Insert 107-3 has a wire head welding post, which connects to the head end of the winding lead 109. Both inserts 107-1 and 107-2 have terminals at their ends, and diodes are connected across these terminals and fixed by soldering. Figure 6 The coil assembly is encapsulated with insulating material to form a plastic sleeve for the coil assembly, exposing only the connection ends in front of the plugs 107-1 and 107-3 used for power connection.

[0169] It should be noted that when the coil winding is connected in series with diode D, a freewheeling diode should be connected in parallel across the coil winding. Figure 1 (Not shown in the image).

[0170] like Figure 8 The upper and lower magnetic inner sleeves 113 and 114 are respectively assembled with an L-shaped iron frame and inserted into the two ends of the coil frame cylinder; the two L-shaped iron frames are snapped together at their ends and fixed on the plastic sleeve 116 of the coil assembly 109 to form a magnetic yoke 111.

[0171] like Figure 8 and Figure 10 In this embodiment, the inlet valve body assembly includes a return spring 200 and a movable iron core 201 installed in the water-proof sleeve 117; a rubber flow hole plug 202; a plastic valve plug 203 with a flow hole 210; a rubber valve plug 204; a valve body 205; a mounting bracket 206; a pressure reducing ring 207; a rubber gasket 208; and a filter screen assembly 209.

[0172] The valve body 205 includes an inlet 215, an outlet 216, and a connector 217, with threads on the inner side of the connector.

[0173] A rubber valve plug 204, a plastic valve plug 203, and a rubber flow hole plug 202 are sequentially installed on the upper end of the valve body 205. The movable iron core 201 is located between the return spring 200 and the rubber flow hole plug 202.

[0174] Mounting bracket 206, pressure reducing ring 207, rubber gasket 208, and filter assembly 209 are sequentially installed on the inlet side of valve body 205.

[0175] The upper cavity of the water-separating sleeve 117 is cylindrical and is installed in the cylinder of the coil frame. The lower cavity of the water-separating sleeve has threads on its outer side, which are threaded to the valve body connector 217. The upper cavity of the water-separating sleeve contains a movable iron core and a return spring located above the movable iron core. A rubber flow-through plug is located below the movable iron core. The water-separating sleeve and the plastic valve plug together form the upper cavity of the valve plug. The plastic valve plug has a flow-through hole that connects the upper cavity of the valve plug to the outlet. The rubber valve plug 204 has a balance hole 213 that connects the upper cavity of the valve plug to the inlet. The return spring 200 has a certain pre-compression. When the valve is not energized, the movable iron core falls due to its own weight and spring force, causing the rubber flow-through plug to seal the flow-through hole.

[0176] like Figures 1-5 As shown, after connectors 107-1 and 107-3 are connected to the AC power supply, the current from the AC power supply enters through connector 107-1, passes through the diode to connector 107-2, then enters the winding through the lead wire tail welding post 126 and the end of the winding lead wire, flows out through the lead wire head welding post 125, and reaches the other end of the AC power supply through connector 107-3. A freewheeling diode (not shown in the figure) can be soldered between the lead wire head welding post 125 and the lead wire tail welding post 126.

[0177] like Figure 10 The aforementioned current generates a magnetic field in the winding, driving the movable iron core upward to compress the return spring. This causes the rubber flow hole plug to move upward, opening the flow hole. The water pressure drops to the rubber valve plug in front of the balance hole, pressing it upward and causing the plastic valve plug to rise, thus opening the valve and connecting the inlet and outlet, i.e., opening the solenoid valve. After power is cut off, the magnetic field generated by the winding disappears, the return spring extends, pushing the rubber flow hole plug downward, closing the flow hole. The water pressure passes through the balance hole and presses down on the rubber and plastic valve plugs to reset, interrupting the flow between the inlet and outlet, and closing the inlet valve.

[0178] Example 2:

[0179] Compared with the prior art, this embodiment uses copper-clad aluminum wire or aluminum wire with a larger wire diameter instead of copper wire, and the winding is connected in series with the resistor. For example... Figures 11-29 As shown, the coil assembly includes a winding 109, a coil frame 104, a magnetic yoke 111, an upper magnetic inner sleeve 113, a lower magnetic inner sleeve 114, inserts 107-1, 107-2, 107-3, and a resistor. Figure 13The coil frame is a cylindrical plastic part with an end face at one end, and a positioning boss 110 is provided on the end face; for example Figure 14 A magnetically conductive sleeve positioning ring 106 is provided at the middle position inside the coil frame cylinder, and the diameter of the positioning ring is slightly smaller than the diameter of the coil frame cylinder. Figure 16 The winding is wound around a cylindrical coil frame, with the two ends of the winding forming the start and end points of the lead wires, respectively. For example... Figures 12 to 15 Inserts 107-1, 107-2, and 107-3 are insulated from each other and inserted into the end face of the coil frame. Inserts 107-1 and 107-3 are used for connection to the power supply, and are arranged parallel to each other, with the length of insert 107-1 being greater than the length of insert 107-3. Insert 107-2 is located behind insert 107-3 in the same direction. Insert 107-2 has a wire tail welding post, which connects to the tail end of the winding lead. Insert 107-3 has a wire head welding post, which connects to the head end of the winding lead.

[0180] like Figure 11 , 17 As shown in Figure 18, electronic component 108 is a resistor R. Terminals are provided at the ends of both insert 1 and insert 107-2, connected via resistor R. The magnetic yoke is specifically designed as a U-shaped iron frame with positioning grooves and through holes on its upper and lower end faces. The positioning groove 112 of the magnetic yoke is engaged with the positioning boss on the end face of the coil frame, and the through hole is aligned with the center of the coil frame cylinder. The upper and lower magnetic inner sleeves pass through the upper and lower through holes via interference fits and are positioned at both ends inside the coil frame cylinder.

[0181] like Figure 19 The coil assembly is encapsulated with insulating material to form a plastic sleeve for the coil assembly, exposing the connecting ends in front of the plugs 107-1 and 107-3 for power connection, as well as the inner walls of the upper and lower magnetic inner sleeves.

[0182] like Figure 23 In this embodiment, the inlet valve includes a valve body 205, a plastic valve plug 203, a rubber valve plug 204, a movable iron core 201, a plastic-encapsulated coil assembly 101-2 with a magnetic yoke, and a welding cover 120. The plastic-encapsulated coil assembly 101-2 with a magnetic yoke includes components such as a water-proof sleeve 117 and a coil assembly 109 (see...). Figure 22 The valve body 205 includes an inlet 215, an outlet 216, and a connector 217, the connector having threads on its inner side. Figure 21 , 22 The water-sealing sleeve is formed by secondary injection molding based on the encapsulated coil assembly. Upper and lower magnetically conductive inner sleeves cover the coil frame cylinder to form the upper cavity. The top of the water-sealing sleeve is not injection molded, leaving a hole communicating with the upper cavity. A welded cap made of plastic is welded to the water-sealing sleeve, sealing the hole at the top. The lower cavity of the water-sealing sleeve has threads on the outside, which connect to the valve body connector. Figure 23The upper cavity of the water-tight sleeve contains a movable iron core and a return spring located above the movable iron core. A rubber flow hole plug is located below the movable iron core. For example... Figure 25 The water-sealing sleeve and the plastic valve plug together form the upper cavity of the valve plug. The plastic valve plug has a flow hole connecting the upper cavity of the valve plug to the water outlet. The rubber valve plug has a balance hole connecting the upper cavity of the valve plug to the water inlet. The return spring has a certain pre-compression; when the valve is not energized, the movable iron core falls due to its own weight and spring force, causing the rubber flow hole plug to seal the flow hole.

[0183] like Figure 18 As shown, after connectors 107-1 and 107-3 are connected to the AC power supply, the current from one end of the AC power supply enters through connector 107-1, passes through electronic components (such as resistors) to connector 107-2, then enters the winding through the wire tail welding post and the winding lead end, flows out through the winding lead end and the wire head welding post, and reaches the other end of the AC power supply through connector 107-3. Figure 25 The aforementioned current generates a magnetic field in the winding, driving the movable iron core upward to compress the return spring. This causes the rubber flow hole plug to move upward, opening the flow hole. The water pressure drops to the rubber valve plug in front of the balance hole, pressing it upward and causing the plastic valve plug to rise, thus opening the valve and connecting the inlet and outlet, i.e., opening the solenoid valve. After power is cut off, the magnetic field generated by the winding disappears, the return spring extends, pushing the rubber flow hole plug downward, closing the flow hole. The water pressure passes through the balance hole and presses down on the rubber and plastic valve plugs to reset, interrupting the flow between the inlet and outlet, and closing the inlet valve.

[0184] The difference between Example 3 and Example 2 is that the electronic component 108 is a diode D and a resistor R connected in series, such as... Figure 30 As shown.

[0185] As an option, such as Figure 31 As shown, the steps of assembling the coil frame with a coil winding of D turns and other components of the water inlet solenoid valve according to the present invention include: installing a magnetic yoke on the coil assembly and then encapsulating it to form a encapsulated coil assembly 400 with a magnetic yoke; using the upper magnetic inner sleeve 113, the limiting member 106 and the lower magnetic inner sleeve 114 placed together as inserts for injection molding to form an independent water-proof sleeve assembly 300; and assembling the encapsulated coil assembly 400 with a magnetic yoke, the water-proof sleeve assembly 300 and the valve body assembly together to complete the assembly of the integrated water inlet solenoid valve.

[0186] As an option, such as Figure 32As shown, the assembly steps of the present invention of a coil frame with a coil winding of D turns and other components of a water inlet solenoid valve include: installing inserts on the coil frame with the coil winding and then encapsulating it to form a plastic-encapsulated coil assembly 500 without a magnetic yoke; using the upper magnetic inner sleeve 113, the limiting member 106 and the lower magnetic inner sleeve 114 placed together as inserts for injection molding to form an independent water-proof sleeve assembly 300; and assembling the plastic-encapsulated coil assembly 500 without a magnetic yoke, the magnetic yoke 111, the water-proof sleeve assembly 300 and the valve body assembly together to complete the assembly of the integrated water inlet solenoid valve.

[0187] For the limiting member 106, there is the following variant design: by setting a positioning structure in the mold cavity, such as a step or positioning rib, the upper magnetic inner sleeve 113 and the lower magnetic inner sleeve 114 are spaced apart in the mold cavity, and a magnetic inner sleeve positioning ring 106 is formed during injection molding.

[0188] As an option, such as Figure 33 As shown, the assembly steps of the present invention of a coil frame with a coil winding of D turns and other components of a water inlet solenoid valve include: a coil assembly formed by mounting the coil winding and inserts onto the coil frame; injection molding a water-proof sleeve as an insert or base using an upper magnetic sleeve 113 and a lower magnetic sleeve 114 to form a magnetic sleeve water-proof sleeve assembly; mounting a magnetic yoke onto the coil assembly; inserting the water-proof sleeve assembly with the magnetic sleeve into the cavity of the coil assembly and performing injection molding to seal it; thus forming an integrated encapsulated stator assembly 100 that encapsulates the coil assembly, the magnetic yoke, and the water-proof sleeve assembly.

[0189] The integrated inlet solenoid valve is assembled by combining the integrated stator assembly 100 and the valve body assembly. The lower cavity of the integrated stator assembly 100 has a thread 118 on its outer side, which is threaded to the main valve seat / valve body connector.

[0190] In summary, this invention can save copper usage while ensuring the normal start-up of the inlet solenoid valve; it can also use aluminum wire as the coil winding without changing the volume of the inlet solenoid valve; and by injection molding a water-proof sleeve in the stator assembly, the thickness of the water-proof sleeve can be greatly reduced, thereby improving the electromagnetic attraction force on the driving movable iron core.

[0191] Although the present invention has been described in detail above, it is not limited thereto, and those skilled in the art can make various modifications based on the principles of the present invention. Therefore, all modifications made in accordance with the principles of the present invention should be understood to fall within the protection scope of the present invention.

Claims

1. A method for implementing a water inlet solenoid valve, the method comprising: With the rated voltage range of the inlet solenoid valve maintained at 200V to 240V AC, a coil winding with a number of turns D lower than the standard number of turns B of the coil winding is wound on the coil frame, and then the coil frame with the coil winding with the number of turns D is assembled with the other components of the inlet solenoid valve. During the start-up of the solenoid valve using 200V to 240V AC power, the current flowing through the coil winding with the number of turns D during the start-up of the inlet solenoid valve is reduced, and a current adapted to the resistance value of the coil winding with the number of turns D is provided, so as to prevent the temperature rise caused by the reduction in the resistance value of the coil winding due to the reduction in the number of turns of the coil winding. Wherein, the standard number of turns B of the coil winding is 14,000 to 16,000 turns as required by conventional design, and the number of turns D that is lower than the standard number of turns B of the coil winding is between 0.54B and 0.65B.

2. The method according to claim 1, wherein, By connecting a current-limiting element in series in the power supply circuit of the coil winding, the current flowing through the coil winding with D turns is reduced.

3. The method according to claim 2, wherein, The coil frame is provided with a first plug that connects one end to the live wire or neutral wire of the power supply, a second plug that connects one end to the neutral wire or live wire of the power supply and the other end to the coil winding, and a third plug that connects one end to the coil winding; the current limiting element is installed between the other end of the first plug and the other end of the third plug.

4. The method according to claim 1, wherein, The coil winding wire diameter of the number of turns D is at least 0.01 mm smaller than that of the coil winding of the standard number of turns B; the number of turns D is 9000 turns; the coil winding is a copper enameled wire winding.

5. A method for implementing a water inlet solenoid valve, the method comprising: With the rated voltage range of the inlet solenoid valve maintained at 100V to 127V AC, a coil winding with a number of turns D lower than the standard number of turns B of the coil winding is wound on the coil frame, and then the coil frame with the coil winding with the number of turns D is assembled with the other components of the inlet solenoid valve. During the activation of the solenoid valve using 100V to 127V AC power, the current flowing through the coil winding with the number of turns D during the activation of the inlet solenoid valve is reduced, and a current adapted to the resistance value of the coil winding with the number of turns D is provided, so as to prevent the temperature rise caused by the reduction in the resistance value of the coil winding due to the reduction in the number of turns of the coil winding. The standard number of turns B of the coil winding is 6700-7700 turns as required by conventional design, and the number of turns D that is lower than the standard number of turns B of the coil winding is between 0.51B and 0.96B.

6. The method according to claim 5, wherein, By connecting a current-limiting element in series in the power supply circuit of the coil winding, the current flowing through the coil winding with D turns is reduced; Wherein, the number of turns D below the standard number of turns B of the coil winding is between 0.51B and 0.64B, and the wire diameter of the coil winding with the number of turns D is at least 0.01mm smaller than the wire diameter of the coil winding with the standard number of turns B; the coil winding is a copper enameled wire winding.

7. The method according to claim 5, wherein, By connecting a current-limiting element in series in the power supply circuit of the coil winding, the current flowing through the coil winding with D turns is reduced; Wherein, the number of turns D below the standard number of turns B of the coil winding is between 0.56B and 0.72B, and the wire diameter of the coil winding with the number of turns D is at least 0.02mm smaller than the wire diameter of the coil winding with the standard number of turns B; the coil winding is a copper enameled wire winding.

8. The method according to claim 5, wherein, By connecting a current-limiting element in series in the power supply circuit of the coil winding, the current flowing through the coil winding with D turns is reduced; Wherein, the number of turns D below the standard number of turns B of the coil winding is between 0.75B and 0.96B, and the wire diameter of the coil winding with the number of turns D is at least 0.01mm larger than the wire diameter of the coil winding with the standard number of turns B; the coil winding is a copper-clad aluminum or aluminum enameled wire winding.

9. The method according to claim 6, 7, or 8, wherein, The coil frame is provided with a first plug that connects one end to the live wire or neutral wire of the power supply, a second plug that connects one end to the neutral wire or live wire of the power supply and the other end to the coil winding, and a third plug that connects one end to the coil winding; the current limiting element is installed between the other end of the first plug and the other end of the third plug.

10. The method according to any one of claims 1-8, wherein, The step of assembling the coil frame with the coil winding of number D turns with other components of the water inlet solenoid valve includes: A stator assembly is formed by installing an upper magnetic inner sleeve and a lower magnetic inner sleeve in the hole of the coil assembly, and fixing the magnetic yoke connecting the upper magnetic inner sleeve and the lower magnetic inner sleeve to the coil assembly; Based on the stator assembly, a stator assembly with a water-proof sleeve is produced by molding. The assembly of the inlet solenoid valve is completed by assembling the stator assembly with the water-proof sleeve and the valve body assembly together.

11. The method according to any one of claims 1-8, wherein, The step of assembling the coil frame with the coil winding of number D turns with other components of the water inlet solenoid valve includes: After the magnetic yoke is installed on the coil assembly, it is encapsulated to form an encapsulated coil assembly with a magnetic yoke. The upper and lower magnetic inner sleeves, placed together, are injection molded to form a water-proof sleeve assembly. The water inlet solenoid valve is assembled by combining the encapsulated coil assembly with magnetic yoke, the water-proof sleeve assembly, and the valve body assembly.

12. The method according to any one of claims 1-8, wherein, The step of assembling the coil frame with the coil winding of number D turns with other components of the water inlet solenoid valve includes: By installing inserts on the coil frame of the wound coil and then encapsulating it, a plastic-encapsulated coil assembly without a magnetic yoke is formed; The upper and lower magnetic inner sleeves, placed together, are injection molded to form a water-proof sleeve assembly. The water inlet solenoid valve is assembled by combining the encapsulated coil assembly without a magnetic yoke, the magnetic yoke, the water-proof sleeve assembly, and the valve body assembly.

13. The method according to any one of claims 1-8, wherein, The step of assembling the coil frame with the coil winding of number D turns with other components of the water inlet solenoid valve includes: A coil assembly is formed by mounting coil windings and inserts onto a coil frame; The upper and lower magnetic inner sleeves, placed together, are injection molded to form a waterproof sleeve assembly. The magnetic yoke is installed onto the coil assembly, and the water-proof sleeve assembly with a magnetic conductive sleeve is inserted into the cavity of the coil assembly. Injection molding is then performed to form an integrated molded stator assembly that molds the coil assembly, the magnetic yoke, and the water-proof sleeve assembly. The integrated plastic-encapsulated stator assembly and valve body assembly are assembled together to complete the assembly of the water inlet solenoid valve.

14. An integrated water inlet solenoid valve implemented according to any one of claims 1-13.

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