SOLENOID VALVE WITH BARB SEALING ARRANGEMENT

Abstract

A valve may include a valve housing having a port portion and a spool support portion extending along a longitudinal axis, a piston located within the valve housing and extending at least partially through the spool support portion, a cap at least partially press-fitted into a first end of the valve housing, and a stop at least partially press-fitted into a second, opposite end of the valve housing. The cap may include a valve seat selectively engageable by a valve cone mounted to the piston to selectively open and close a flow path through the valve housing. The stop may limit movement of the piston away from the cap.The cap and / or stop may include an annular barb extending around a periphery thereof and sealingly securing the cap and / or stop at least partially within the valve housing.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application relates to commonly owned applications entitled "SOLENOID PLUNGER ALIGNMENT", "VALVE WITH IMPROVED MAGNETIC FLUX INTERFACE", "SOLENOID VALVE POPPET AFFIXMENT" and "PRESS TO SPECIFICATION SOLENOID VALVE ASSEMBLY", respectively, each filed on the same date as the present application, the contents of which are incorporated herein by reference. STATE OF THE ART

[0002] Technical Field of the Invention. The present disclosure relates generally to solenoid valves and, more particularly, to miniature solenoid valves. Description of the related technology.

[0003] Solenoid valves typically require internal sealing. However, as these valves become increasingly smaller, the use of sealants such as O-rings becomes more challenging in terms of both assembly and tolerancing. Other sealants, such as adhesives, complicate manufacturing because they are sticky, require time to cure, and carry the risk of over- or under-application. Adhesives also add an additional wet material that may need to be evaluated for leaching, outgassing, and general chemical compatibility. SUMMARY OF THE INVENTION

[0004] Applicants have created novel and useful devices, systems, and methods for solenoid valves. In at least one embodiment, a valve may include a valve housing having a terminal portion and a coil support portion extending along a longitudinal axis, a piston located within the valve housing and extending at least partially through the coil support portion, a cap at least partially press-fitted into the valve housing at a first end of the valve housing, a stop at least partially press-fitted into the valve housing at a second, opposite end of the valve housing, or any combination thereof. In at least one embodiment, the cap, the stop, or both may include an annular barb that sealingly mates with the valve housing.

[0005] In at least one embodiment, the cap may include a valve seat that is selectively engageable by a valve cone mounted to the piston to selectively open and close a flow path through the port portion of the valve housing. In at least one embodiment, the cap may include a barb. In at least one embodiment, the barb may extend around a perimeter of the cap. In at least one embodiment, the barb may withstand pressure within the valve housing to hold the cap in place within the valve housing. In at least one embodiment, the barb may be integral with the cap and / or may seal the cap to the valve housing without an additional sealant. In at least one embodiment, the barb and / or the cap may be made of metal. In at least one embodiment, the valve housing may be made of a compliant material.In at least one embodiment, the barb deforms the valve housing, such as while being press-fitted therein, thereby sealing the cap to the valve housing. In at least one embodiment, the cap may include an annular barb extending around a perimeter of the cap. In at least one embodiment, the cap may include two or more annular barbs extending around a perimeter of the cap. In at least one embodiment, the barb(s) may withstand pressure within the valve housing to hold the cap in place within the valve housing.

[0006] In at least one embodiment, the stop can limit movement of the piston away from the cap. In at least one embodiment, the stop can include a barb. In at least one embodiment, the barb can extend around a perimeter of the stop. In at least one embodiment, the barb can withstand pressure within the valve housing to hold the stop in place within the valve housing. In at least one embodiment, the barb can be integral with the stop and / or can seal the stop to the valve housing without an additional sealant. In at least one embodiment, the barb and / or the stop can be made of metal. In at least one embodiment, the valve housing can be made of a compliant material.In at least one embodiment, the barb can deform the valve housing, such as while being press-fitted therein, thereby sealing the stop to the valve housing. In at least one embodiment, the stop can comprise an annular barb extending around a perimeter of the stop. In at least one embodiment, the stop can comprise two or more annular barbs extending around a perimeter of the stop. In at least one embodiment, the barb(s) can withstand pressure within the valve housing to hold the stop in place within the valve housing.

[0007] In at least one embodiment, a valve may include a valve housing having a port portion and a spool support portion extending along a longitudinal axis, a piston located within the valve housing and extending at least partially through the spool support portion, a cap at least partially press-fitted into the valve housing at a first end of the valve housing, a stop at least partially press-fitted into the valve housing at a second, opposite end of the valve housing, or any combination thereof. In at least one embodiment, the cap may include a valve seat selectively engageable by a valve plug mounted to the piston to selectively open and close a flow path through the port portion of the valve housing.In at least one embodiment, the cap may include a first annular barb extending around a periphery of the cap and sealingly securing the cap at least partially within the valve housing. In at least one embodiment, the stop may limit movement of the piston away from the cap. In at least one embodiment, the stop may include a second annular barb extending around a periphery of the stop and sealingly securing the stop at least partially within the valve housing.

[0008] In at least one embodiment, the first barb can withstand pressure within the valve housing to hold the cap in place within the valve housing. In at least one embodiment, the first barb and the cap can be integrally formed. In at least one embodiment, the first barb and the cap can be integrally formed from metal. In at least one embodiment, the first barb and / or the cap can be made of metal. In at least one embodiment, the valve housing can be made of a compliant material. In at least one embodiment, the first barb can deform the valve housing, thereby sealing the cap to the valve housing.

[0009] In at least one embodiment, the second barb can withstand pressure within the valve housing to hold the stop in place within the valve housing. In at least one embodiment, the second barb and the stop can be integrally formed. In at least one embodiment, the second barb and the stop can be integrally formed from metal. In at least one embodiment, the second barb and / or the stop can be made from metal. In at least one embodiment, the second barb can deform the valve housing, thereby sealing the stop to the valve housing. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view of one of many embodiments of a solenoid valve according to the disclosure. Fig. 2 is a cross-sectional view of a portion of one of many embodiments of a solenoid valve according to the disclosure. Fig. 3 is a cross-sectional view of a portion of another of many embodiments of a solenoid valve according to the disclosure. Fig. 4 is a perspective cross-sectional view of one of many embodiments of a valve plug according to the disclosure. Fig. 5 is a cross-sectional view of a portion of yet another of many embodiments of a solenoid valve according to the disclosure. Fig. 6 is a perspective cross-sectional view of another of many embodiments of a valve plug according to the disclosure. Fig. 7 is a perspective cross-sectional view of a portion of the valve cone of Fig. 6. Fig. 8 is a cross-sectional view of a portion of yet another of many embodiments of a solenoid valve according to the disclosure. Fig. 9 is an exploded cross-sectional view of a portion of one of many embodiments of a valve plug according to the disclosure. Fig. 10 is a cross-sectional view of a portion of one of many embodiments of a solenoid valve according to the disclosure. Fig. 11 is a cross-sectional view of another portion of one of many embodiments of a solenoid valve according to the disclosure. Fig. 12 is a perspective view of one of many embodiments of a cap according to the disclosure. Fig. 13 is an elevational view of one of many embodiments of a stop according to the disclosure. Fig. 14 is a perspective view of the attack of Fig. 13. Fig. 15 is an elevational view of another of many embodiments of a stop according to the disclosure. Fig. 16 is a cross-sectional view illustrating one of many embodiments of an assembly method according to the disclosure prior to press-fitting the valve plug onto the piston. Fig. 17 is a cross-sectional view illustrating another of many embodiments of an assembly method according to the disclosure and showing the valve plug press-fitted onto the piston. Fig. 18 is a cross-sectional view illustrating yet another of many embodiments of an assembly method according to the disclosure prior to press-fitting the cap into the valve body. Fig. 19 is a cross-sectional view illustrating yet another of many embodiments of an assembly method according to the disclosure and showing the cap press-fitted into the valve body. Fig. 20 is a pneumatic circuit diagram of one of many embodiments of a mounting system according to the disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] The figures described above and the written description below of specific structures and functions are not intended to limit the scope of applicants' invention or the scope of the appended claims. Rather, the figures and written description are provided to teach one skilled in the art how to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that, for clarity and understanding, not all features of a commercial embodiment of the inventions are described or illustrated. Those skilled in the art will also appreciate that developing an actual commercial embodiment incorporating aspects of the present inventions will require numerous implementation-specific decisions to achieve the designer's ultimate goal for the commercial embodiment.Such implementation-specific decisions may include, but are not likely limited to, compliance with system-related, business-related, regulatory, and other constraints, which may vary depending on the specific implementation, location, and time. While the development effort may be complex and time-consuming in an absolute sense, it would be a routine undertaking for those skilled in the art with the benefit of this disclosure. It is understood that the inventions disclosed and taught herein are susceptible to numerous and varied modifications and alternative forms.

[0011] The use of a singular term, such as, but not limited to, "a / an," is not intended to limit the number of things. The use of relational terms, such as, but not limited to, "top," "bottom," "left," "right," "upper," "lower," "bottom," "top," "side," and the like, in the written description is for clarity with specific reference to the figures and is not intended to limit the scope of the inventions or the appended claims. The terms "comprising" and "such as" are intended to be illustrative, not limiting.The terms "connect," "connected," "joined," "connection," "connector," and similar expressions are used broadly herein and may include any method or device for securing, binding, joining, fastening, attaching, joining, inserting, molding onto or into, engaging, or otherwise connecting, for example, mechanically, magnetically, electrically, chemically, operatively, directly, or indirectly, to intermediate elements of one or more parts of links, and may further include, without limitation, the integral formation of one functional element with another into a unit. The connection may be in any direction, including rotationally.Furthermore, all parts and components of the disclosure that can be physically embodied generally include imaginary and real features, regardless of whether those features are expressly described herein, including, but not limited to, features such as axes, ends, inner and outer surfaces, interiors, tops, bottoms, sides, boundaries, dimensions (e.g., height, length, width, thickness), mass, weight, volume, and density, to name a few.

[0012] All flowcharts discussed herein illustrate the operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in a flowchart may represent a module, segment, or portion of code that may include one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some implementations, the function or functions specified in the block(s) may occur in a different order than illustrated in the figures. For example, blocks illustrated sequentially may in fact execute substantially concurrently.It should also be noted that each block of the flowchart representation can be implemented by special hardware-based systems that perform the specified functions or actions, or by combinations of special hardware and computer instructions.

[0013] Applicants have created novel and useful devices, systems, and methods for solenoid valves. By press-fitting a valve plug onto a piston, press-fitting a cap into a valve body, press-fitting a stop into a valve body, or any combination thereof, it is possible to simplify valve manufacturing, eliminate parts, reduce costs, accommodate operational adjustments, and / or reduce or eliminate accumulated tolerances.

[0014] Fig. 1 is a cross-sectional view of one of many embodiments of a solenoid valve according to the disclosure. Fig. 2 is a cross-sectional view of a portion of one of many embodiments of a solenoid valve according to the disclosure. Fig. 3 is a cross-sectional view of a portion of another of many embodiments of a solenoid valve according to the disclosure. Fig. 4 is a perspective cross-sectional view of one of many embodiments of a valve plug according to the disclosure. Fig. 5 is a cross-sectional view of a portion of yet another of many embodiments of a solenoid valve according to the disclosure. Fig. 6 is a perspective cross-sectional view of another of many embodiments of a valve plug according to the disclosure. Fig. 7 is a perspective cross-sectional view of a portion of the valve cone of Fig. 6. Fig. 8 is a cross-sectional view of a portion of yet another of many embodiments of a solenoid valve according to the disclosure. Fig. 9 is an exploded cross-sectional view of a portion of one of many embodiments of a valve plug according to the disclosure. Fig. 10 is a cross-sectional view of a portion of one of many embodiments of a solenoid valve according to the disclosure. Fig. 11 is a cross-sectional view of another portion of one of many embodiments of a solenoid valve according to the disclosure. Fig. 12 is a perspective view of one of many embodiments of a cap according to the disclosure. Fig. 13 is an elevational view of one of many embodiments of a stop according to the disclosure. Fig. 14 is a perspective view of the attack of Fig. 13. Fig. 15 is an elevational view of another of many embodiments of a stop according to the disclosure. Fig. 16 is a cross-sectional view illustrating one of many embodiments of an assembly method according to the disclosure prior to press-fitting the valve plug onto the piston. Fig. 17 is a cross-sectional view illustrating another of many embodiments of an assembly method according to the disclosure and showing the valve plug press-fitted onto the piston. Fig. 18 is a cross-sectional view illustrating yet another of many embodiments of an assembly method according to the disclosure prior to press-fitting the cap into the valve body. Fig. 19 is a cross-sectional view illustrating yet another of many embodiments of an assembly method according to the disclosure and showing the cap press-fitted into the valve body. Fig. 20 is a pneumatic circuit diagram of one of many embodiments of a mounting system according to the disclosure. Fig. 1-20 are described in connection with each other.

[0015] In at least one embodiment, a valve 100 according to the disclosure, such as a miniature solenoid valve, may include one or more valve bodies 200, one or more pistons 300 disposed at least partially within the valve body 200, one or more valve plugs 400 connected to the piston 300, one or more end caps 500 connected at least partially within the valve body 200, one or more stops 600 connected at least partially within the valve body 200, or any combination thereof. In at least one embodiment, a valve 100 may include a shell 150 for receiving or protecting one or more components of the valve. In at least one embodiment, the valve plug 400 may be press-fitted onto the piston 300.In at least one embodiment, the cap 500 and / or the stop 600 may limit the movement of the piston 300 and / or the valve cone 400. In at least one embodiment, the cap 500 and / or the stop 600 may be press-fitted into the valve housing 200.

[0016] In at least one embodiment, the valve housing 200 may include one or more port portions 210, one or more flux collar support portions 220, one or more coil support portions 230, or any combination thereof extending along one or more axes, such as a central longitudinal axis X. In at least one embodiment, the port portion 210 may include one or more common ports 212, one or more normally open ports 214, and one or more normally closed ports 216, or any combination thereof. In at least one embodiment, the flux collar support portion 220 may support a flux collar, for example, to improve the efficiency of the valve 100.In at least one embodiment, the connection portion 210, the flux collar support portion 220, and the coil support portion 230 of the valve housing 200 may be a unitary or monolithic structure, for example, by being portions of a one-piece structure (e.g., an injection-molded structure).

[0017] In at least one embodiment, the piston 300 may extend at least partially through the flux collar support portion 220 and the coil support portion 230. In at least one embodiment, the piston 300 may extend at least partially through a flux collar supported by the flux collar support portion 220. In at least one embodiment, the piston 300 may include one or more rods 310 extending into the port portion 210. In at least one embodiment, the piston 300 may include one or more valve plugs 400 mounted to the rod 310. In at least one embodiment, one or more biasing elements 330, such as a spring, may bias the piston 300 and / or the valve plug 400 toward or away from one or more caps 500.

[0018] In at least one embodiment, the coil support portion 230 of the valve housing 200 may include one or more annular walls 232 and / or one or more coils 234. In at least one embodiment, the wall 232 may support the coil 234, which may selectively actuate or move the piston 300 against the force of the spring 330 to thereby transition the valve 100 from a normally open position to a normally closed position. In at least one embodiment, the coil support portion 230 may include one or more stops 600, such as a core and / or related structure, to limit the movement of the piston 300 in one or more directions within the bore 242. In at least one embodiment, the stop 600 may be a single, unitary structure. In at least one embodiment, the stop 600 may be made up of or include a plurality of structures.

[0019] In at least one embodiment, a valve 100 according to the disclosure may include one or more valve plugs 400 press-fitted onto the piston 300 and configured to selectively open and close at least one flow path through the port portion 210 of the valve housing 200. In at least one embodiment, the piston 300 may include a rod 310 extending into the port portion 210 of the valve housing 200. In at least one embodiment, the valve plug 400 may include one or more shoulders 410 against which the spring 330 may bear and thereby bias the valve plug 400 toward a normal operating position, thereby opening a normally open flow path through the valve housing 210 and / or closing a normally closed flow path through it.In at least one embodiment, the coil 234 may overcome the spring 330 to move the piston 300 and the valve plug 400 to close a normally open flow path through the valve body 210 and / or open a normally closed flow path therethrough.

[0020] In at least one embodiment, the valve plug 400 may be press-fitted onto the rod 310. In at least one embodiment, the rod 310 may include one or more annular barbs 320 configured to engage an interior surface of the valve plug 400 to hold the valve plug 400 in place on the rod 310. In at least one embodiment, the rod 310 may include an annular barb 320 configured to engage an interior surface of the valve plug 400 to hold the valve plug 400 in place on the rod 310. In at least one embodiment, the rod 310 may include a plurality of annular barbs 320 configured to engage an interior surface of the valve plug 400 to hold the valve plug 400 in place on the rod 310.

[0021] In at least one embodiment, the valve plug 400 may include one or more annular grooves 420 configured to engage the barb(s) 320 on the rod 310 to hold the valve plug 400 in place on the rod 310. In at least one embodiment, the valve plug 400 may include an annular groove 420 configured to engage the barb(s) 320 on the rod 310 to hold the valve plug 400 in place on the rod 310. In at least one embodiment, the valve plug 400 may include a plurality of annular grooves 420 configured to engage the barb(s) 320 on the rod 310 to hold the valve plug 400 in place on the rod 310.In at least one embodiment, the annular barbs 320 and / or the annular groove(s) 420 may enable adjustment of a position of the valve plug 400 relative to the rod 310 such that the valve plug 400 may be mounted along a range of positions along the rod 310.

[0022] In at least one embodiment, the valve plug 400 may be a single unit or comprised of multiple sections. In at least one embodiment, the valve plug 400 may include a stiffer section 430 configured to engage the barb 320 on the rod 310. In at least one embodiment, the valve plug 400 may include a more compliant section configured to selectively engage one or more valve seats 240, 540 to selectively open and close the flow path through the port portion 210 of the valve body 200. In at least one embodiment where the stiff section 430 is harder or stiffer than the compliant section 440, the stiff section 430 may better hold the valve plug 400 in place along the rod 310 of the piston 300.In at least one embodiment where the compliant portion 440 is more compliant, softer, and / or more elastomeric than the rigid portion 430, the compliant portion 440 may seal better with the valve seats 240, 540. In at least one embodiment, the compliant portion 440 may be at least partially drawn into, through, or onto the rigid portion 430. In at least one embodiment, the rigid portion 430 may include one or more annular flanges 432. In at least one embodiment, the compliant portion 440 may include one or more slots 442 configured to mate with the flange 432.

[0023] In at least one embodiment, the valve plug 400 may include one or more bands 450 around a circumference of the valve plug 400 for securing the valve plug 400 to the rod 310. In at least one embodiment, the valve plug 400 may be at least partially threaded into or through the band 450. In at least one embodiment, the band 450 may be made of metal and / or crimped onto the valve plug 400, thereby securing the valve plug 400 to the rod 310. In at least one embodiment, the band 450 may be made of a stiffer polymer than the valve plug 400 or its compliant portion 440, thereby supporting and / or securing the valve plug 400 to the rod 310.

[0024] In at least one embodiment, the valve cone 400 can selectively engage one or more valve seats 240, 540 to selectively open and close one or more flow paths through the port portion 210 of the valve housing 200. In at least one embodiment, one or more valve seats 240 can be integral with the valve housing 200 and / or part of a normally open or normally closed flow path. In at least one embodiment, one or more valve seats 540 can be integral with a cap 500 that is press-fitted into one end of the valve housing 200.

[0025] In at least one embodiment, the valve cone 400 may include one or more seals 460, such as gasket(s) or O-ring(s), configured to selectively engage one or more valve seats 240, 540 to selectively open and close one or more flow paths through the port portion 210 of the valve housing 200. In at least one embodiment, the valve cone 400 may include a first seal 460 configured to selectively engage a first valve seat 540 to selectively open and close a normally closed flow path through the port portion 210 of the valve housing 200.In at least one embodiment, the valve plug 400 may include a second seal 460 configured to selectively engage a second valve seat 240 to selectively open and close a normally open flow path through the port portion 210 of the valve housing 200. In at least one embodiment, the seal(s) 460 may be mounted to the valve plug 400 and / or the stem 310, with the valve plug 400 selectively pressing the seal(s) 460 into the valve seats 240, 540.

[0026] In at least one embodiment, portions of the valve housing 200 and / or the cap 500 may be compliant. In at least one embodiment, the entire valve cone 400 or portions thereof may be rigid. In at least one embodiment, the valve cone 400 may be rigid and configured to selectively engage a valve seat 240, 540 to selectively open and close the flow path through the port portion 210 of the valve housing 200.

[0027] In at least one embodiment, a valve 100 according to the disclosure, such as a miniature or other solenoid valve, may include one or more valve housings 200 having a port portion 210 and a coil support portion 230 extending along a longitudinal axis, one or more pistons 300 located within the valve housing 200 and extending at least partially through the coil support portion 230, a valve cone 400 including a compliant portion 440 configured to selectively engage a rigid valve seat 240, 540 to open and close at least one flow path through the port portion 210 of the valve housing 200, or any combination thereof. In at least one embodiment, the piston 300 may include one or more rods 310 extending into the port portion 210 of the valve housing 200.In at least one embodiment, the rod 310 may include at least one annular barb 320 configured to engage an inner surface of the valve cone 400 to hold the valve cone 400 in place on the rod 310. In at least one embodiment, one or more of the valve seats 240 may be integral with the valve housing 200. In at least one embodiment, one or more of the valve seats 540 may be integral with a cap 500 that is press-fitted into one end of the valve housing 200.

[0028] In at least one embodiment, the valve plug 400 may include one or more rigid portions 430 configured to engage the barb 320 on the stem 310. In at least one embodiment, the rigid portion 430 may be harder than the compliant portion 440. In at least one embodiment, the rigid portion 430 may include one or more annular flanges 432. In at least one embodiment, the compliant portion 440 may be configured to mate with the flange 432 and / or include one or more slots 442 configured to mate with the flange 432.

[0029] In at least one embodiment, a valve 100 according to the disclosure, such as a miniature or other solenoid valve, may include one or more valve housings 200 having a port portion 210 and a coil support portion 230 extending along a longitudinal axis, one or more pistons 300 located within the valve housing 200 and extending at least partially through the coil support portion 230, one or more valve cones 400 configured to selectively engage one or more valve seats 240, 540 to open and close one or more flow paths through the port portion 210 of the valve housing 200, or any combination thereof. In at least one embodiment, the piston 300 may include a rod 310 extending into the port portion 210 of the valve housing 200. In at least one embodiment, the rod 310 may include one or more annular barbs 320.In at least one embodiment, the barbs 320 may engage an inner surface of the valve cone 400 to hold the valve cone 400 in place on the rod 310.

[0030] By press-fitting the valve plug 400 onto the stem 310 of the piston 300, it is possible to simplify the manufacturing of the valve 100, eliminate parts, reduce costs, make operational adjustments, and / or reduce or eliminate accumulated tolerances. For example, a valve plug body or retainer may be eliminated. In at least one embodiment, the valve plug 400 according to the disclosure does not require a complex and / or expensive overmolding process. In at least one embodiment, the valve plug 400 according to the disclosure may incorporate a variety of techniques, as described above, to provide sufficient retention force or resistance to pull-out to remain in place on the piston 300 for proper functionality within the valve 100.In at least one embodiment, the valve plug 400 according to the disclosure may be a monolithic or unitary elastomeric or otherwise compliant structure having an integrated shoulder 410 for the spring 330 to provide a biasing force thereagainst to actuate the valve 100. In at least one embodiment, one or more of the barbs 320 and / or grooves 420 may be spiral-shaped, thereby enabling the valve plug 400 according to the disclosure to be press-fitted and / or threaded onto the stem 310 while still obtaining many or all of the advantages discussed herein.

[0031] In at least one embodiment, an outer surface of the rod 310 and / or an inner surface of the valve plug 400 may be rough or roughened to increase stiction between the rod 310 and the valve plug 400. In at least one embodiment, a dissolvable and / or evaporable lubricant may be used during assembly of the valve 100, for example, to temporarily reduce friction between the rod 310 and the valve plug 400. In at least one embodiment, an adhesive may be used to bond the rod 310 and the valve plug 400. In at least one embodiment, the valve plug 400 may include a through-hole for injecting an adhesive between the rod 310 and the valve plug 400. In at least one embodiment, the valve plug 400 may be configured to allow the transfer of heat or ultraviolet light to the adhesive between the rod 310 and the valve plug 400.In at least one embodiment, the valve plug 400 of the disclosure may be vulcanized, cured, shrinked, or a combination thereof once it is in place on the stem 310. In at least one embodiment, the valve plug 400 of the disclosure, or a portion thereof, may be made of metal and / or a rigid polymer, and / or the valve seats 240, 540 may be made of metal and / or a rigid polymer, with the valve 100 relying on a metal-to-metal and / or metal-to-plastic seal, thereby eliminating elastomeric materials in sealing the flow path(s).

[0032] In at least one embodiment, a valve 100 according to the disclosure may include one or more caps 500 that are at least partially press-fitted into the valve housing 200 at one end of the valve housing 200, such as at the port portion 210 of the valve housing. In at least one embodiment, the cap 500 may include one or more valve seats 540 that are selectively engageable by the valve cone 400 mounted to the piston 300 to selectively open and close a flow path through the port portion 210 of the valve housing 200. In at least one embodiment, the cap 500 may include one or more annular barbs 520 that sealingly mate with the valve housing 200. In at least one embodiment, the barb 520 may extend around a perimeter of the cap 500.In at least one embodiment, the barb 520 can withstand pressure within the valve housing 200 to hold the cap 500 in place within or relative to the valve housing 500. In at least one embodiment, the annular barb(s) 520 can enable adjustment of a position of the cap 500 within the valve housing 200 such that the cap 500 can be mounted along a range of positions along the valve housing 200. By adjusting the position of the cap 500 within or relative to the valve housing 200, it is possible to adjust the stroke of the piston 300 and one or more flow rates through the port portion 210 of the valve housing, reduce accumulated tolerances in the valve 100, or any combination thereof.

[0033] In at least one embodiment, the barb 520 may be integral with the cap 500 and / or may hermetically or fluidly seal the cap 500 to the valve housing 200, including without the need for an additional sealing means, such as an O-ring, gasket, or sealant. In at least one embodiment, the barb 520 and / or the cap 500 may be made of metal and / or the valve housing 200 may be made of a compliant material. In at least one embodiment, the barb 520 may deform the valve housing 200, such as while being press-fitted therein, thereby sealing the cap 500 to the valve housing 200.

[0034] In at least one embodiment, the cap 500 may include an annular barb 520 extending around a perimeter of the cap 500. In at least one embodiment, the cap 500 may include two or more annular barbs 520 extending around a perimeter of the cap 500. In at least one embodiment, the barbs 520 may withstand pressure within the valve housing 200 to hold the cap 500 in place within or relative to the valve housing 200.

[0035] In at least one embodiment, a valve 100 according to the disclosure may include one or more stops 600 that are at least partially press-fitted into the valve housing 200 at one end of the valve housing 200, such as at the spool portion 230 of the valve housing 200. In at least one embodiment, the stop 600 may include one or more stems 610 for limiting movement of the piston 300 away from (i.e., in a direction away from) the cap 500 and / or a flange 612 that can be used to fix a position of the stop 600 relative to the valve housing 200. In at least one embodiment, the stop 600 may include one or more annular barbs 620 that sealingly mate with the valve housing 200. In at least one embodiment, the barb 620 may extend around a perimeter of the stop 600.In at least one embodiment, the barb 620 may extend around a circumference of the stem 610 and / or the flange 612. In at least one embodiment, the barb 620 may withstand pressure within the valve housing 200 to hold the stop 600 in place within or relative to the valve housing 200. In at least one embodiment, the annular barb(s) 620 may enable adjustment of a position of the stop 600 within or relative to the valve housing 200 such that the stop 600 may be mounted along a range of positions along the valve housing 200. By adjusting the position of the stop 600 within or relative to the valve housing 200, it is possible to adjust the stroke of the piston 300 and / or reduce accumulated tolerances in the valve 100.

[0036] In at least one embodiment, the barb 620 may be integral with the stop 600 and / or may hermetically or fluidly seal the stop 600 to the valve housing 200, including doing so on its own, such as without the aid of an additional sealing means, such as an O-ring, gasket, or sealant. In at least one embodiment, the barb 620 and / or the stop 600 may be made of metal and / or the valve housing 200 may be made of a compliant material. In at least one embodiment, the barb 620 may be configured to deform the valve housing 200, such as while being press-fitted therein, thereby sealing the stop 600 to the valve housing 200.

[0037] In at least one embodiment, the stop 600 may include one or more annular barbs 620 extending around a perimeter of the stop 600. In at least one embodiment, the stop 600 may include two or more annular barbs 620 extending around a perimeter of the stop 600. In at least one embodiment, the barbs 620 may withstand pressure within the valve housing 200 and / or hold the stop 600 in place within or relative to the valve housing 200.

[0038] In at least one embodiment, a valve 100 according to the disclosure may include one or more valve housings 200 having a port portion 210 and a coil support portion 230 extending along a longitudinal axis, a piston 300 located within the valve housing 200 and extending at least partially through the coil support portion 230, a cap 500 at least partially press-fitted into the valve housing 200 at a first end of the valve housing 200, a stop 600 at least partially press-fitted into the valve housing 200 at a second, opposite end of the valve housing 200, or any combination thereof.In at least one embodiment, the cap 500 may include a valve seat 540 configured to be selectively engaged by a valve cone 400 mounted to the piston 300 to selectively open and close a flow path through the port portion 210 of the valve housing 200. In at least one embodiment, the cap 500 may include one or more first annular barbs 520 extending around a circumference of the cap 500 that can sealingly secure the cap 500 at least partially within the valve housing 200. In at least one embodiment, the stop 600 may limit movement of the piston 300 away from the cap 500. In at least one embodiment, the stop 600 may include one or more second or other annular barbs 620 extending around a circumference of the stop 600 that can sealingly secure the stop 600 at least partially within the valve housing 200.

[0039] In at least one embodiment, the first barb 520 can withstand pressure within the valve housing 200 to hold the cap 500 in place within the valve housing 200 or relative thereto. In at least one embodiment, the first barb 520 can be made of metal. In at least one embodiment, the first barb 520 and the cap 520 can be integrally formed from metal. In at least one embodiment, the valve housing 200 can be made of a resilient material. In at least one embodiment, the first barb 520 can deform the valve housing 200, such as while being press-fitted therein, thereby sealing the cap 500 to the valve housing 200.

[0040] In at least one embodiment, the second barb 620 can withstand pressure within the valve housing 200 to hold the stop 600 in place within the valve housing 200 or relative to it. In at least one embodiment, the barb can be made of metal. In at least one embodiment, the second barb and the stop can be integrally formed from metal. In at least one embodiment, the valve housing can be made of a compliant material. In at least one embodiment, the second barb can deform the valve housing, such as while being press-fitted therein, thereby sealing the stop 600 to the valve housing.

[0041] The use of barbs 520, 620 on the cap 500 and / or the stop 600, all of which may be made of metal, advantageously provides retention and / or a hermetic seal within the valve body 200, which may be made of plastic or polymer, thereby eliminating the need for additional parts to function, reducing the number of required parts, reducing the time and / or labor required for assembly, enabling positional fixation and / or adjustment within the valve body 200, or any combination thereof. In at least one embodiment, the cap 500 may include two or more barbs 520 to prevent angular deviation of the valve seat 540 relative to the valve body 200 and / or the piston 400.In at least one embodiment, heat may be used to shrink, insert, and / or further connect or seal the valve housing 200 to the cap 500 and / or the stop 600.

[0042] In at least one embodiment, a valve 100 according to the disclosure may include one or more valve housings 200 having a port portion 210 and a spool support portion 230 extending along a longitudinal axis, a piston 300 located within the valve housing 200 and extending at least partially through the spool support portion 230, a valve cone 400 press-fitted onto the piston 300, or any combination thereof. In at least one embodiment, the housing 200 may include one or more first valve seats 240. In at least one embodiment, the piston 300 may include a rod 310 extending through the first valve seat 240 into the port portion 210. In at least one embodiment, the valve cone 400 may be press-fitted onto the rod 310 of the piston 400.In at least one embodiment, the valve cone 400 can selectively engage the first valve seat 240 to open and close a first flow path through the connecting portion 210 of the valve housing 200. In at least one embodiment, a stroke of the piston 300 and / or a volumetric flow through the first flow path can be adjusted by adjusting a first position of the valve cone 400 on the piston 300.

[0043] In at least one embodiment, a valve 100 according to the disclosure may include one or more caps 500 that are at least partially press-fitted into the connecting portion 210 of the valve housing 200. In at least one embodiment, the cap 500 may include one or more second valve seats 540. In at least one embodiment, the valve cone 400 may selectively engage the second valve seat 540 to open and close a second flow path through the connecting portion 210 of the valve housing 200. In at least one embodiment, a stroke of the piston 300 and / or a volumetric flow through the second flow path may be adjusted by adjusting a second position of the cap 500 in or relative to the housing 200.

[0044] In at least one embodiment, a method of assembling a valve 100 according to the disclosure may include monitoring a first flow between a first port and a second port of the valve 100 and / or pressing a valve cone 400 onto a piston 300 of the valve 100 until the first flow stops. In at least one embodiment, a method of assembling a valve 100 according to the disclosure may include monitoring a second fluid flow between the first port and a third port of the valve 100, energizing a coil 234 of the valve 100, pressing a cap 500 into a housing 200 of the valve 100 until the second fluid flow stops, or any combination thereof.In at least one embodiment, a method of assembling a valve 100 according to the disclosure may include monitoring a second fluid flow between the first port and a third port of the valve 100 and / or pressing a cap 500 into a housing 200 of the valve 100 until a desired rate of second fluid flow is achieved. In at least one embodiment, the first port may be a common port. In at least one embodiment, the second port may be a normally closed port. In at least one embodiment, the third port may be a normally open port.

[0045] In at least one embodiment, a mounting system or apparatus 700, such as that described in Fig.20, to provide a controlled fluid flow to / from one or more ports of the port portion 210 of the valve housing 200 during assembly of the valve 100. In at least one embodiment, such fluid flow may be air, another inert gas, water, another inert fluid, or any combination thereof. In at least one embodiment, the system 700 may be or include a pneumatic system, one or more assembly fixtures (not shown), and one or more presses or pressing machines (not shown), such as a dynamic precision press capable of precisely pressing components based on closed-loop sensor feedback. In at least one embodiment, the system 700 may include one or more supply pressure inlets, one or more solenoid valves (e.g.,Solenoid valves SV1, SV2 and following), one or more pressure regulators (e.g. pressure regulators PR1, PR2), one or more flow meters (e.g. flow meter FM), one or more level meters (e.g. level meter LM), one or more pressure transmitters (e.g. pressure transmitter PT), one or more orifices, one or more valve connection connections, one or more vents or any combination thereof.

[0046] In at least one embodiment, a method of assembling a valve 100 according to the disclosure may include monitoring a current draw of the coil 234 and continuing to press the cap 500 into the housing 200 and / or the valve cone 400 onto the piston 300 until the current draw corresponds to a desired setting value. By adjusting the position of the cap 500 in or relative to the housing 200 and / or the valve cone 400 on the piston 300, the current draw of the coil 234 may be controlled.

[0047] In at least one embodiment, a method of assembling a valve 100 according to the disclosure may include energizing a coil 234 of the valve 100, de-energizing the coil 234 of the valve 100, and monitoring for a noise caused by a piston 300 of the valve 100 contacting a stop 600 of the valve 100. In at least one embodiment, a method of assembling a valve 100 according to the disclosure may include repeating the steps of pressing the valve cone 400 onto the piston 300, energizing the coil 234 of the valve 100, de-energizing the coil 234 of the valve 100, monitoring for the noise caused by the piston 300 contacting the stop 600, or any combination thereof, until the noise caused by the piston 300 contacting the stop 600 is no longer detected.By adjusting the position of the valve cone 400 on the piston 300, the stroke of the piston 300 can be controlled, for example to limit the engagement between the piston 300 and the stop 600.

[0048] In at least one embodiment, a method of assembling a valve 100 according to the disclosure may include monitoring a first flow between a common port and a normally closed port of the valve 100, pressing a valve cone 400 onto a piston 300 of the valve 100 until the first flow stops, monitoring a second fluid flow between the common port and a normally open port of the valve 100, energizing a coil 234 of the valve 100, pressing a cap 500 into a housing 200 of the valve 100 until the second fluid flow stops, or any combination thereof.In at least one embodiment, the method of assembling a valve 100 according to the disclosure may further include monitoring a current draw of the coil 234 and / or continuing to press or repeatedly press the cap 500 into the housing 200 and / or the valve cone 400 onto the piston 300 until the current draw corresponds to a desired setting. In at least one embodiment, the method of assembling a valve 100 according to the disclosure may further include energizing the coil 234 of the valve 100, de-energizing the coil 234 of the valve 100, monitoring for noise caused by a piston 300 of the valve 100 contacting a stop 600 of the valve 100, or any combination thereof.In at least one embodiment, the method of assembling a valve 100 according to the disclosure may further include repeating the steps of pressing the valve cone 400 onto the piston 300, energizing the coil 234 of the valve 100, de-energizing the coil 234 of the valve 100, monitoring for the noise caused by the piston 300 contacting the stop 600, or any combination thereof, until the noise caused by the piston 300 contacting the stop 600 is no longer detected. In at least one embodiment, the valve cone 400 may be pressed onto the piston 300 before the cap 500 is pressed into the housing 200.

[0049] By monitoring the volumetric flows through the connecting portion 210 of the valve 100 during the pressing of the valve cone 400 onto the piston 300 and / or the cap 500 into the housing 200, the position of the valve cone 400 on the piston 300 and / or the cap 500 in the housing 200 can be adjusted, thereby reducing, eliminating, or otherwise mitigating effects of accumulated tolerances in the valve 100, such as those affecting the stroke of the piston 300. Further pressing the valve cone 400 onto the piston 300 and / or further pressing the cap 500 into the housing 200 allows for adjustment of the stroke of the piston 300, the flow through the port portion of the valve 100, the current draw of the coil 234, the operating noise within the valve 100, the tension and / or preload of the spring 330, or any combination thereof.The assembly method described herein has the potential to reduce costs through increased tolerances (i.e., adjustability reduces the effect of tolerances and thereby allows for tighter tolerances in the manufacture of individual components), provide better performance by reducing excessive elastomer deformation at the valve seats 240, 540, mitigate leakage in the energized state by performing a compression operation until sufficient elastomer deformation has occurred to provide an adequate seal between the cap 500 and the housing 200 and / or between the stop 600 and the housing 200, provide precise flow control, provide variability in flow rates without changing the orifice size, increase the reliability of the valve 100 (e.g., because functionality can be confirmed during assembly), or any combination thereof.Accumulated tolerances may be mitigated by the use of the annular barbs 320, 520, 620 described herein, by threaded barbs, by part sorting (to compensate for tolerances), or by any combination thereof.

[0050] In at least one embodiment, a valve may include a valve housing having a port portion and a coil support portion extending along a longitudinal axis, a piston located within the valve housing and extending at least partially through the coil support portion, a cap at least partially press-fitted into the valve housing at a first end of the valve housing, a stop at least partially press-fitted into the valve housing at a second, opposite end of the valve housing, or any combination thereof. In at least one embodiment, the cap, the stop, or both may include an annular barb that sealingly mates with the valve housing.

[0051] In at least one embodiment, the cap may include a valve seat selectively engageable by a valve cone mounted to the piston to selectively open and close a flow path through the port portion of the valve body. In at least one embodiment, the cap may include a barb. In at least one embodiment, the barb may extend around a perimeter of the cap. In at least one embodiment, the barb may withstand pressure within the valve body to hold the cap in place within or relative to the valve body. In at least one embodiment, the barb may be integral with the cap and / or may seal the cap to the valve body, which may include doing so without an additional gasket or sealant. In at least one embodiment, the barb and / or the cap may be made of metal.In at least one embodiment, the valve housing may be made of a compliant material. In at least one embodiment, the barb deforms the valve housing, such as while being press-fitted therein, thereby sealing the cap to the valve housing. In at least one embodiment, the cap may include an annular barb extending around a perimeter of the cap. In at least one embodiment, the cap may include two or more annular barbs extending around a perimeter of the cap. In at least one embodiment, the barb(s) may withstand pressure within the valve housing to hold the cap in place within or relative to the valve housing.

[0052] In at least one embodiment, the stop can limit movement of the piston away from or in a direction away from the cap. In at least one embodiment, the stop can include a barb. In at least one embodiment, the barb can extend around a perimeter of the stop. In at least one embodiment, the barb can withstand pressure within the valve housing to hold the stop in place within or relative to the valve housing. In at least one embodiment, the barb can be integral with the stop and / or can seal the stop to the valve housing, such as without the aid of an additional sealant. In at least one embodiment, the barb and / or the stop can be made of metal. In at least one embodiment, the valve housing can be made of a compliant material.In at least one embodiment, the barb can deform the valve housing, such as while being press-fitted therein, thereby sealing the stop to the valve housing. In at least one embodiment, the stop can comprise an annular barb extending around a perimeter of the stop. In at least one embodiment, the stop can comprise two or more annular barbs extending around a perimeter of the stop. In at least one embodiment, the barb(s) can withstand pressure within the valve housing to hold the stop in place within or relative to the valve housing.

[0053] In at least one embodiment, a valve may include a valve housing having a port portion and a spool support portion extending along a longitudinal axis, a piston located within the valve housing and extending at least partially through the spool support portion, a cap at least partially press-fitted into the valve housing at a first end of the valve housing, a stop at least partially press-fitted into the valve housing at a second, opposite end of the valve housing, or any combination thereof. In at least one embodiment, the cap may include a valve seat selectively engageable by a valve plug mounted to the piston to selectively open and close a flow path through the port portion of the valve housing.In at least one embodiment, the cap may include a first annular barb extending around a periphery of the cap and sealingly securing the cap at least partially within the valve housing. In at least one embodiment, the stop may limit movement of the piston in one or more directions, such as away from the cap. In at least one embodiment, the stop may include a second annular barb extending around a periphery of the stop and sealingly securing the stop at least partially within the valve housing.

[0054] In at least one embodiment, the first barb can withstand pressure within the valve housing to hold the cap in place within or relative to the valve housing. In at least one embodiment, the first barb and the cap can be integrally formed. In at least one embodiment, the first barb and the cap can be integrally formed from metal. In at least one embodiment, the first barb and / or the cap can be made of metal. In at least one embodiment, the valve housing can be made of a compliant material. In at least one embodiment, the first barb can deform the valve housing, thereby sealing the cap to the valve housing.

[0055] In at least one embodiment, the second barb can withstand pressure within the valve housing to hold the stop in place within or relative to the valve housing. In at least one embodiment, the second barb and the stop can be integrally formed. In at least one embodiment, the second barb and the stop can be integrally formed from metal. In at least one embodiment, the second barb and / or the stop can be made from metal. In at least one embodiment, the second barb can deform the valve housing, thereby sealing the stop to the valve housing.

[0056] Other and further embodiments utilizing one or more aspects of the disclosure may be devised without departing from the spirit of Applicants' disclosure. For example, the devices, systems, and methods may be implemented for numerous different types and sizes in numerous different industries. Furthermore, the various methods and embodiments of the devices, systems, and methods may be incorporated in combination with one another to produce variations of the disclosed methods and embodiments. The discussion of individual elements may include multiple elements, and vice versa. The order of steps may take a variety of sequences unless expressly limited otherwise. The various steps described herein may be combined with other steps, interspersed with recited steps, and / or divided into multiple steps.The elements are also described functionally and can be implemented as standalone components or combined to form components with multiple functions.

[0057] The inventions have been described in connection with preferred and alternative embodiments, and not every embodiment of the inventions has been described. Obvious modifications and variations of the described embodiments will be apparent to those skilled in the art and having the benefit of the present disclosure. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the inventions conceived by the applicants; rather, in accordance with patent law, the applicants wish to fully protect all such modifications and improvements that fall within the scope or range of the equivalents of the following claims.

Claims

[1] Valve comprising: a valve housing having a terminal portion and a coil support portion extending along a longitudinal axis; a piston located within the valve housing and extending at least partially through the coil support portion; a cap which is at least partially press-fitted into the valve housing at a first end of the valve housing; and a stop which is at least partially press-fitted into the valve housing at a second, opposite end of the valve housing; wherein at least one of the cap and the stop comprises an annular barb that sealingly mates with the valve body. [2] The valve of claim 1, wherein the cap includes the barb; wherein the barb extends around a perimeter of the cap; and wherein the barb is configured to withstand pressure within the valve housing to hold the cap in place relative to the valve housing. [3] The valve of claim 2, wherein the barb is integral with the cap and configured to fluidly seal the cap to the valve body. [4] The valve of claim 3, wherein the barb and cap are made of metal and the valve body is made of a resilient material; and wherein the barb is configured to deform the valve body and thereby seal the cap to the valve body. [5] The valve of claim 2, wherein the barb is made of metal and the valve body is made of a resilient material; and wherein the barb is configured to deform the valve body and thereby seal the cap to the valve body. [6] The valve of claim 1, wherein the cap includes at least two annular barbs extending around a periphery of the cap; and wherein the barbs are configured to withstand pressure within the valve housing to hold the cap in place relative to the valve housing. [7] The valve of claim 1, wherein the cap includes a valve seat configured to be selectively engaged by a valve cone mounted on the piston to selectively open and close a flow path through the port portion of the valve body. [8] The valve of claim 1, wherein the stop comprises the barb; wherein the barb extends around a perimeter of the stop; and wherein the barb is configured to withstand pressure within the valve housing to hold the stop in place relative to the valve housing. [9] The valve of claim 8, wherein the barb is integral with the stop and configured to fluidly seal the stop to the valve housing. [10] The valve of claim 9, wherein the barb and the stop are made of metal and the valve body is made of a resilient material; and wherein the barb is configured to deform the valve body and thereby seal the stop to the valve body. [11] The valve of claim 8, wherein the barb is made of metal and the valve body is made of a resilient material; and wherein the barb is configured to deform the valve body and thereby seal the stop to the valve body. [12] The valve of claim 1, wherein the stop comprises at least two annular barbs extending around a periphery of the stop; and wherein the barbs are configured to withstand pressure within the valve housing to hold the stop in place relative to the valve housing. [13] The valve of claim 1, wherein the stop is configured to limit movement of the piston in a direction away from the cap. [14] Valve comprising: a valve housing having a terminal portion and a coil support portion extending along a longitudinal axis; a piston located within the valve housing and extending at least partially through the coil support portion; a cap at least partially press-fitted into the valve housing at a first end of the valve housing, the cap including a valve seat configured to be selectively engaged by a valve cone mounted on the piston to selectively open and close a flow path through the port portion of the valve housing, and the cap including a first annular barb extending around a periphery of the cap and sealingly securing the cap at least partially within the valve housing; and a stop at least partially press-fitted into the valve housing at a second, opposite end of the valve housing, the stop being configured to limit movement of the piston in a direction away from the cap, and the stop including a second annular barb extending around a periphery of the stop and sealingly securing the stop at least partially within the valve housing. [15] The valve of claim 14, wherein the first barb is configured to withstand pressure within the valve housing to hold the cap in place relative to the valve housing. [16] The valve of claim 14, wherein the first barb and the cap are integrally formed from metal and the valve housing is made from a resilient material; and wherein the first barb is configured to deform the valve housing and thereby seal the cap to the valve housing. [17] The valve of claim 14, wherein the first barb is made of metal and the valve body is made of a resilient material; and wherein the first barb is configured to deform the valve body and thereby seal the cap to the valve body. [18] The valve of claim 14, wherein the second barb is configured to withstand pressure within the valve housing to hold the stop in place relative to the valve housing. [19] The valve of claim 14, wherein the second barb and the stop are integrally formed from metal and the valve housing is made from a resilient material; and wherein the second barb is configured to deform the valve housing and thereby seal the stop to the valve housing. [20] The valve of claim 14, wherein the barb is made of metal and the valve housing is made of a resilient material; and wherein the second barb is configured to deform the valve housing and thereby seal the stop to the valve housing.

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