Stator assembly with water isolation sleeve, method of manufacturing same, and water solenoid valve with said stator assembly

Abstract

To provide a solenoid valve for water which reinforces an electro-magnetic force acting on a movable iron core, and a manufacturing method therefor.SOLUTION: A manufacturing method for a stator assembly provided with a water-separating sleeve 117 applied to a solenoid valve for water includes: a step which forms a coil assembly having a cavity by fitting an element including an insert 107 to a coil rack 104 around which a coil winding 109 is wound; a step which forms the stator assembly by fitting an upper magnetic conductivity inner sleeve 113 and a lower magnetic conductivity inner sleeve 114 to a hole of the coil rack of the coil assembly and fixing a yoke 111 connecting the upper magnetic conductivity inner sleeve and the lower magnetic conductivity inner sleeve to the outside of the coil assembly; and a step which ejects resin to the stator assembly and forms the stator assembly provided with the water-separating sleeve.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to the technical field of manufacturing solenoid valves for water, and more particularly to a solenoid valve for water that can increase electromagnetic attraction force, and a method for manufacturing the same. [Background technology]

[0002] A water solenoid valve (or water supply valve) functions to control the supply or cut-off of a water resource. Since water has a constant pressure, the valve can be configured as a packless pilot-operated water solenoid valve during operation. Figure 1 shows the structure of a current water solenoid valve that is more commonly used. This water solenoid valve includes a resin sealing layer 116 for resin sealing a coil winding, a magnetic yoke 111 attached to the outside of the resin sealing layer, a plug 107, a water inlet 215, and a water outlet 216.

[0003] 1 shows a solenoid valve for water that is essentially composed of two parts: a pilot valve and a primary valve. When no voltage is applied to the winding 109, the movable core 201 falls due to its own weight and the reaction force of the return spring, closing the flow hole 210 of the primary valve plug 203. Therefore, the upper cavity of the valve plug 203 is exposed to the balance hole 213. 211The water that has entered the valve plug diaphragm cannot escape, and the difference in the effective support area between the top and bottom of the valve diaphragm creates a pressure difference, which presses the valve plug diaphragm against the primary valve seat, closing the valve. When a voltage is applied to the winding 109, the magnetic force pulls the movable core 201 upward, and the water in the upper cavity 211 of the valve plug diaphragm is discharged to the outlet of the valve through the flow hole 210. Since the flow rate of the flow hole is configured to be much higher than the flow rate of the balance hole 213, the water flow creates a sufficient pressure loss in the balance hole 213, causing the pressure in the upper cavity 211 of the valve plug to decrease rapidly, while the pressure in the lower cavity 212 of the valve plug is maintained at the same pressure as the inlet pressure, so that the pressure difference between the upper and lower sides of the valve plug diaphragm causes the valve plug diaphragm to bulge upward, opening the valve.

[0004] The main problem of the water solenoid valve shown in FIG. 1 is that the water isolation sleeve 117 must be manufactured separately. The manufactured water isolation sleeve is inserted into the magnetic conductive inner sleeve by assembly. Therefore, the water isolation sleeve 117 mounted in the center hole of the coil rack 104 needs to have a certain thickness to resist the pressure impact when the valve is closed and to resist possible structural damage during mechanical assembly. As a result, the non-working gap of the existing water solenoid valve is larger than 1.5 mm, and therefore a larger electromagnetic force is required to work the movable iron core. In addition, manufacturing the water isolation sleeve separately increases the manufacturing cost. Also, since the yoke 111 is attached outside the resin sealing layer 116 of the resin-encapsulated coil winding, the yoke 111 needs to be welded together with the magnetic conductive inner sleeve to fix the yoke to the coil rack through the magnetic conductive inner sleeve, which increases the welding process and manufacturing cost.

[0005] The enameled windings of commercially available water solenoid valves all use a total of 26.5 to 28 grams of copper wire. Reducing the amount of copper wire is the simplest way to reduce costs. However, reducing the amount of copper wire inevitably affects the performance of the water solenoid valve. By improving the magnetic circuit structure, it is possible to reduce the amount of copper wire used and achieve a balance between performance and cost, on the premise of maintaining or even improving the performance level of the water supply valve. This is the problem to be solved by the present invention. Summary of the Invention [Problem to be solved by the invention]

[0006] One object of the present invention is to provide a water solenoid valve capable of increasing electromagnetic force, and to provide a manufacturing method for a water solenoid valve that strengthens the electromagnetic force acting on the movable iron core, simplifies the manufacturing process of the water solenoid valve, and reduces manufacturing costs. [Means for solving the problem]

[0007] According to a first aspect of the present invention, a method for manufacturing a stator assembly with a water isolation sleeve for use in a water solenoid valve includes the steps of: placing an element including an insert on a coil rack having a hole with a coil winding wound thereon to form a coil assembly having a hole; forming a stator assembly by installing the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve in a state where the upper magnetic conductive inner sleeve is inserted into an upper end of a hole of the coil rack of the coil assembly and the lower magnetic conductive inner sleeve is inserted into a lower end of the hole, and fixing a yoke connecting the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve to an outside of the stator assembly; injecting a resin onto an outer surface of the stator assembly to form a resin sealing layer covering the coil winding and the yoke, thereby manufacturing a primary sealed resin sealed assembly; injecting resin onto an inner surface of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve of the primary resin encapsulation assembly to form a water isolation sleeve on the inner surface of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve, thereby manufacturing a stator assembly including the water isolation sleeve. It is characterized by the following.

[0009] Preferably, the coil rack hole has a magnetically conductive inner sleeve positioning ring for positioning the upper magnetically conductive inner sleeve and the lower magnetically conductive inner sleeve so as to maintain the upper magnetically conductive inner sleeve and the lower magnetically conductive inner sleeve at a predetermined distance in the coil rack hole.

[0010] Preferably, at the same time as injecting resin into the primary resin-encapsulated stator assembly, a water isolation sleeve base is formed at the lower end of the water isolation sleeve, and the water isolation sleeve base is used to connect and fix a valve body assembly of the water solenoid valve.

[0011] According to a second aspect of the present invention, there is provided a method for manufacturing a stator assembly with a water isolation sleeve for use in a water solenoid valve, comprising the steps of: forming a water isolation sleeve by injecting resin onto an inner surface of the upper magnetic conductive inner sleeve, the magnetic conductive inner sleeve positioning ring, and the lower magnetic conductive inner sleeve to form a water isolation sleeve assembly including the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve; placing an element including an insert in a coil rack having a hole with a coil winding wound therein and fastening a yoke connecting the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve to the outside of the coil rack to form a coil assembly; inserting the upper magnetic conductive inner sleeve, the magnetic conductive inner sleeve positioning ring, and portions of the lower magnetic conductive inner sleeve of the water isolation sleeve assembly into holes in a coil rack of the coil assembly to form a stator assembly including the water isolation sleeve, the upper magnetic conductive inner sleeve, the lower magnetic conductive inner sleeve, and the coil winding; To manufacture a stator assembly with a water isolation sleeve, the method includes a step of injecting resin onto an outer surface of the stator assembly to form a resin sealing layer that covers the coil windings and the yoke on the stator assembly.

[0012] Preferably, the water isolation sleeve assembly comprises: an upper magnetic conductive inner sleeve secured together by resin injection; Magnetically conductive inner sleeve positioning ring and a lower magnetically conductive inner sleeve; said upper magnetic conductive inner sleeve; said magnetically conductive inner sleeve positioning ring and a water isolation sleeve formed on the inner surface of the lower magnetic conductive inner sleeve by resin injection. a water isolation sleeve base disposed at a lower end of the water isolation sleeve and integrally formed with the water isolation sleeve.

[0013] Preferably, the upper and lower magnetically conductive inner sleeves each have a cylindrical shape, the wall of the cylinder being provided with through holes through which adhesive can flow.

[0014] Preferably, the inner surfaces of the upper and lower magnetically conductive inner sleeves are provided with axial grooves in communication with the radial through holes.

[0015] Preferably, the inner surfaces of the upper and lower magnetically conductive inner sleeves are provided with circumferential grooves in communication with the axial grooves.

[0016] Preferably, the water isolation sleeve and the water isolation sleeve base are formed on the inner surfaces of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve by injecting resin, and during the resin injection, the hot melt resin flows into the radial through hole of the magnetic conductive inner sleeve along the axial groove of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve; Water Isolation Sleeve The base is formed for fixing the

[0017] According to a third aspect of the present invention, there is provided a stator assembly with a water isolation sleeve for use in a water solenoid valve, comprising: A coil winding (109) is wound on a coil rack (104) having holes (125), and an insert (107) is placed on the coil rack (104); An upper magnetically conductive inner sleeve (113) is inserted into the upper end of the hole (125) of the coil rack (104); A lower magnetically conductive inner sleeve (114) is inserted into the lower end of the hole (125) of the coil rack (104); A resin injection molded water isolation sleeve (117) is provided along the inner surface of the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114); A yoke (111) is connected at its upper portion to an upper magnetic conductive inner sleeve (113) and at its lower portion to a lower magnetic conductive inner sleeve (114), The resin sealing layer (116) covers the coil assembly (103) and the yoke (111) such that the upper portion of the yoke (111) is in intimate contact with the upper magnetic conductive inner sleeve (113) and the lower portion of the yoke (111) is in intimate contact with the lower magnetic conductive inner sleeve (114) without covering the portion of the insert (107) electrically connected to the external power source. .

[0018] Preferably, the lower end of the water isolation sleeve is provided with a water isolation sleeve base integrally formed by resin injection, and the water isolation sleeve base is not covered by the resin sealing layer so as to be connected and fixed to the valve body of the water solenoid valve.

[0019] Preferably, the yoke positioning groove of the yoke positions the yoke on the coil rack on the one hand by fastening yoke positioning bosses provided on the upper and lower end faces of the coil rack, and is connected to the upper magnetic conductive inner sleeve on the other hand.

[0020] Preferably, the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve are cylindrical, and each has a water isolation sleeve fixing structure for attaching the water isolation sleeve to the inner surface of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve.

[0021] Preferably, the water isolation sleeve fastening structure includes radial through holes through which adhesive passes.

[0022] Preferably, the water isolation sleeve fixing structure further includes a groove provided on an inner surface of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve.

[0023] Preferably, the groove includes an axial groove in communication with the radial through hole.

[0024] Preferably, the groove includes a circumferential groove in communication with the axial groove.

[0025] According to a fourth aspect of the present invention, The water solenoid valve comprises a valve body assembly and a stator assembly having a water isolation sleeve (100) according to any one of claims 10 to 17, and is formed by assembling the stator assembly having the water isolation sleeve (100) with the valve body assembly. Effect of the Invention

[0026] The advantageous technical effect of the present invention over the prior art is that, through the improvement of the magnetic circuit structure, the end surface attractive force generated by the main magnetic flux is strengthened, the total electromagnetic attractive force is increased when the valve is started, and the low pressure starting performance is improved.

[0027] In addition, by forming a water isolation sleeve on the inner surfaces of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve by injecting resin, the thickness of the water isolation sleeve can be significantly reduced, thereby strengthening the electromagnetic force acting on the movable iron core.

[0028] On the other hand, by fixing the yoke and the coil assembly together by injecting resin, the manufacturing process for manufacturing the water solenoid valve can be simplified, which can reduce the manufacturing cost and improve the manufacturing quality. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 is a schematic diagram showing the structure of a prior art water solenoid valve. [Diagram 2]FIG. 4 is a diagram showing a load reaction force of the movable core with respect to a stroke of the movable core. [Diagram 3] FIG. 2 is a cross-sectional view of the water solenoid valve of the present invention. [Figure 4] FIG. 2 is a cross-sectional view of a resin-encapsulated stator assembly of the water solenoid valve of the present invention. [Diagram 5] FIG. 2 is an exploded view of the stator assembly of the water solenoid valve of the present invention. [Figure 6] FIG. 2 is a perspective view of a stator assembly of the water solenoid valve of the present invention; [Figure 7] FIG. 2 is a cross-sectional view of a primary resin encapsulated stator assembly formed by primary injection of resin into the stator assembly of the water solenoid valve of the present invention; [Figure 8] FIG. 2 is a cross-sectional view of the primary resin encapsulated stator assembly of the water solenoid valve of the present invention; [Figure 9a] FIG. 2 is a front view of a first embodiment of the upper magnetic conductive inner sleeve of the water solenoid valve of the present invention. [Figure 9b] FIG. 9b is a cross-sectional view taken along line AA of FIG. 9a of the present invention. [Figure 9c] FIG. 9b is a cross-sectional view along BB in FIG. 9a of the present invention. [Figure 9d] FIG. 2 is a perspective view of a first embodiment of an upper magnetic conductive inner sleeve of the water solenoid valve of the present invention. [Figure 10] FIG. 1 is a perspective view of a stator assembly with a water isolation sleeve formed by applying the secondary resin fill of the present invention to a primary resin potted stator assembly of a water solenoid valve. [Figure 11] FIG. 2 is a cross-sectional view of a stator assembly with a water isolation sleeve of the water solenoid valve of the present invention; [Figure 12] FIG. 12 is a schematic diagram showing another embodiment of the present invention for forming a water isolation sleeve, showing the positional relationship of an upper magnetic conductive inner sleeve, a lower magnetic conductive inner sleeve, and a stopper as an insert. [Figure 13]FIG. 13 is a schematic diagram showing another embodiment of the present invention for forming a water isolation sleeve. FIG. 13 is a perspective view showing a water isolation sleeve assembly formed by injecting resin into an upper magnetic conductive inner sleeve, a lower magnetic conductive inner sleeve, and a stopper as an insert. [Figure 14] FIG. 14 is a schematic diagram showing another embodiment of the present invention for forming a water isolation sleeve; FIG. 14 is a cross-sectional view of a water isolation sleeve assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the accompanying drawings and embodiments in order to help further understanding of the contents, features, and technical effects of the present invention.

[0031] The present invention will be described first from the structure of the coil rack, the magnetic conductive inner sleeve, the water isolation sleeve, the movable iron core and the magnetic conductive base. By improving the magnetic circuit structure, the present invention enhances the electromagnetic attraction force when the water supply valve starts, reduces water consumption and reduces costs under the premise of meeting the minimum starting voltage requirement.

[0032] The magnetic circuit of the water solenoid valve of the present invention consists of a yoke, a magnetically conductive seat, an upper magnetically conductive inner sleeve, an armature, and a lower magnetically conductive inner sleeve.

[0033] FIG. 2 shows the relationship between the load reaction force of the movable core and the stroke of the movable core, and the load reaction force characteristic acting on the movable core during operation is shown as curve 1 in FIG. 2. In the FS coordinate system, F is the load reaction force acting on the movable core, and S is the suction stroke of the movable core. The load reaction force mainly consists of the water force F1 acting on the movable core, the weight G of the movable core, and the elastic force F2 of the spring, and F1 and F2 are important and variable values. When the movable core closes the flow hole, F1 is equal to the product of the water source pressure and the cross-sectional area of ​​the flow hole, and point A in the figure corresponds to the state of the closed valve, that is, the initial stage of the movable core rising after the power is turned on, and the valve plug diaphragm also rises, so the flow hole cannot be unblocked, and the pressure in the upper cavity of the valve plug continues to decrease, although it still has a force acting on the movable core downward. Then, the spring is compressed and the spring force increases. The first half of curve 1 decreases slowly because F1 decreases faster than F2 increases. At point B, the valve plug diaphragm rises completely, the flow hole is unblocked, F1 disappears completely, and the load reaction force drops rapidly to a minimum. The armature then rises against F2, and the slope of the sloping line after point B is the elastic constant of the spring.

[0034] In order to adapt to the load reaction force characteristics, the electromagnetic attraction force characteristics acting on the movable core are as shown in FIG. 2. The relative positions of the upper magnetic conductive inner sleeve, the lower magnetic conductive inner sleeve and the movable core play an important role in the specific effect of the electromagnetic attraction force. There is a working air gap between the movable core and the upper magnetic conductive inner sleeve, and there is a main non-working air gap between the movable core and the lower magnetic conductive inner sleeve. Before the movable core is sucked into the upper magnetic conductive inner sleeve, the magnetic potential mainly falls into the working air gap, and the electromagnetic attraction force includes the electromagnetic force formed by the leakage magnetic flux on the side of the movable core and the end surface attraction force formed by the main magnetic flux. That is, when the upper end surface of the movable core approaches the lower edge of the upper magnetic conductive inner sleeve, the effect of the end surface attraction force becomes larger. That is, the closer the upper end surface approaches the lower edge of the upper magnetic conductive inner sleeve, the larger the total electromagnetic attraction force becomes, and it reaches a maximum value when the movable core is about to enter the upper magnetic conductive inner sleeve. After the armature is sucked into the upper magnetically conductive inner sleeve, the length of the working air gap does not change, but the area of ​​the air gap increases according to the depth of the armature, and the working air gap magnetic conductivity increases rapidly to a degree that can be equivalent to the magnetic conductivity of the non-working air gap. Thus, the working air gap magnetic pressure drop increases proportionally, thereby reducing the electromagnetic attraction force. The descending part of the electromagnetic attraction force characteristic curve and the ascending part of the load reaction force characteristic curve intersect at point C, the armature is completely sucked in, and the water solenoid valve also functions.

[0035] In view of the fact that the movable core must have a certain suction stroke, there exists magnetic leakage in the gap between the upper magnetic inner sleeve and the lower magnetic inner sleeve, and the magnetic seat is mounted in the upper magnetic inner sleeve. The present invention improves the structure of the magnetic circuit as follows: 1. The upper end surface of the movable core is higher than the upper edge of the lower magnetic conductive inner sleeve and lower than 1 / 4 of the distance between the upper edge of the lower magnetic conductive inner sleeve and the lower edge of the upper magnetic conductive inner sleeve in the initial position (corresponding to the position where the movable core is placed before the power is turned on), so that the upper end surface of the movable core in the initial position is slightly higher than the upper edge of the lower magnetic conductive inner sleeve, and the magnetic leakage of the gap between the upper edge of the lower magnetic conductive inner sleeve and the lower edge of the upper magnetic conductive inner sleeve can fully act on the movable core in the initial position, ensuring that the movable core has a reliable suction stroke, which improves the suction reliability. 2. The socket length between the movable core and the lower magnetic conductive inner sleeve in the initial position (corresponding to the length of the movable core in the initial position in the lower magnetic conductive inner sleeve) is not less than 1 / 4 of the sum of the height of the upper magnetic conductive inner sleeve and the height of the lower magnetic conductive inner sleeve, that is, the length of the movable core can be less than the length of the lower magnetic conductive inner sleeve, but is not less than 1 / 2 of the length of the lower magnetic conductive inner sleeve, so as to ensure that the magnetic conductivity of the non-working air gap is not too small, avoid the saturation of the iron core, and improve the resistance of the water solenoid valve to impulse current impact.

[0036] The specific values ​​are set as follows: The gap between the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve is 2-5mm. The weight of the magnetic conductive seat should be more than 60% of the movable iron core. The diameter of the movable iron core is reduced from 6mm to 5±0.1mm. The inner diameter of the water isolation sleeve is 5.5±0.1mm, the wall thickness is 0.5mm, and the outer diameter is 6.5±0.1mm. The inner diameter of the magnetic conductive inner sleeve is 6.5±0.1mm, the wall thickness is 1mm, and the outer diameter is 8.5±0.1mm. The opening of the hole of the coil rack is about 8.7mm. The wall thickness of the coil rack is reduced from 1mm to 0.4mm.

[0037] As a result of the reduced diameter of the moving core, the noise caused by the attraction and collision between the magnetized magnetic conductive seat and the moving core when voltage is applied to the coil winding is also reduced. The openings of the water isolation sleeve, the upper magnetic conductive inner sleeve, the lower magnetic conductive inner sleeve, and the coil rack are reduced to accommodate the reduced diameter of the moving core. The reduced opening of the coil rack reduces copper wire consumption, reduces winding resistance, and increases current without changing the number of turns and wire diameter of the winding. This improves the electromagnetic attraction and low voltage starting performance.

[0038] The present invention provides a method for implementing a water solenoid valve, which can improve the electromagnetic attraction force. The method includes the steps of obtaining a resin-encapsulated stator assembly by injecting resin into the stator assembly, and assembling the resin-encapsulated stator assembly together with a valve body assembly including a movable iron core 201 to form a water solenoid valve. As shown in Fig. 3, the resin-encapsulated stator assembly of the present invention includes a coil assembly 103 including a coil rack 104, a coil winding 109 wound around the coil rack 104, an insert 107, and an electronic component 108 (see Fig. 5) mounted on the coil rack 104; 103 Hole 125 the coil assembly including an upper magnetic conductive inner sleeve 113 and a lower magnetic conductive inner sleeve 114 attached to the coil assembly, a water isolation sleeve 117 disposed inside the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114, a yoke 111 disposed outside the coil assembly and connecting the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114, a magnetic conductive seat 121 attached inside the upper water isolation sleeve 117, and a resin sealing layer 116 covering the coil assembly and the yoke 111.

[0039] According to the present invention, the upper end surface of the movable core 201 in the initial position is set to be higher than the upper edge of the lower magnetic conductive inner sleeve 114 and lower than 1 / 4 of the distance from the upper edge of the lower magnetic conductive inner sleeve 114 to the lower edge of the upper magnetic conductive inner sleeve 113, so that the electromagnetic attraction force of the water solenoid valve is increased.

[0040] 3, the valve body assembly of the water solenoid valve of the present invention includes a return spring 200 and an armature core 201 housed in a water isolation sleeve, a valve plug rubber 202 with a flow hole, a valve plug 203, a valve plug rubber 204, a valve body 205, a mounting rack 206, a pressure relief ring 207, a rubber gasket 208, a filter screen assembly 209, etc. All of these parts of the valve body assembly of the water solenoid valve are parts of the existing water solenoid valve, and their connection relationships are also almost the same as those of the prior art, and fall within the scope of the prior art. For the sake of brevity, detailed descriptions of those considered to be prior art will be omitted.

[0041] According to the present invention, the length of the movable iron core in the lower magnetic conductive inner sleeve in the initial position is set to be equal to or greater than 1 / 4 of the sum of the height of the upper magnetic conductive inner sleeve and the height of the lower magnetic conductive inner sleeve, thereby ensuring that the magnetic conductivity of the non-working gap is not too small, avoiding the magnetic saturation of the iron core, and improving the resistance of the water solenoid valve to large impulse current impact.

[0042] The specific parameters for realizing the above-mentioned improvement method of the magnetic circuit structure of the present invention include the following: the gap between the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve is 2mm-5mm, the diameter of the movable iron core is reduced from 6mm to 5±0.1mm, the inner diameter of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve is 6.5±0.1mm, the wall thickness is 1mm, the outer diameter is 8.5±0.1mm, the inner diameter of the water isolation sleeve is 5.5±0.1mm, the outer diameter is 6.5±0.1mm, and the weight of the magnetic conductive seat is more than 60% of the weight of the movable iron core, which advantageously increases the magnetic conductivity, increases the electromagnetic attraction force, and strengthens the reliability of the valve suction.

[0043] Referring to FIG. 4, the present invention can form a water isolation sleeve inside the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 by injecting resin inside the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 mounted within the coil assembly.

[0044] 5-11 illustrate a particular process for forming a water isolation sleeve within upper magnetic conductive inner sleeve 113 and lower magnetic conductive inner sleeve 114 in accordance with the present invention.

[0045] As shown in FIG. 5, the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 are Hole 125 4, and the magnetic conductive inner sleeve positioning ring 106 (see FIG. 4) in the hole 125 in the coil rack 104 defines the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 in a position where they can contact the magnetic yoke 111. Then, the yoke positioning grooves 112 of the yoke 111 engage with the yoke positioning bosses 105 on the upper and lower end faces of the coil rack 104, so that the yoke 111 is positioned on the coil rack 104 and is in intimate contact with and coupled to the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114. In this way, the stator assembly 102 shown in FIG. 6 is formed.

[0046] Compared with the prior art, the present invention can omit the welding process of welding the yoke 111 to the upper and lower magnetic conductive inner sleeves, and can omit one yoke. However, in the prior art, it is necessary to weld the upper magnetic conductive inner sleeve to one yoke, weld the lower magnetic conductive inner sleeve to another yoke, and then butt-joint these two yokes (wherein there may be quality issues that the butt-joint cannot be realized). Therefore, according to the present invention, these steps can be omitted, the cost can be reduced, and the product quality can be improved.

[0047] In the present invention, the stator assembly 102 is used as a base or insert, and resin is injected into the stator assembly 100 with the water isolation sleeve. The stator assembly 100 with the water isolation sleeve is manufactured by placing the stator assembly 102 shown in FIG. 6 in a mold and injecting resin in a primary injection, so that the coil winding 109, the yoke 111, and the electronic components 108 are surrounded by resin, and the coil rack with the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 is formed. 104 Hole 125 and the insert 107 are exposed. This forms the primary resin encapsulation assembly 101 shown in Figures 7 and 8. The primary resin encapsulation assembly 101 is placed in another mold and resin is secondarily injected to form the water isolation sleeve 117 into the coil rack 114 including the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114. 104 Inner hole 125 10 and 11 to produce a stator assembly 100 with an integrated water isolation sleeve as shown in FIG.

[0048] FIG. 11 shows an integrated water isolation sleeve. 117The structure of the stator assembly 100 is shown in FIG. 1. The yoke 111 is firmly fixed to the coil assembly 103 by a resin sealing layer 116, and the water isolation sleeve 117 is injection molded on the inner walls of the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114, so that the water isolation sleeve 117 having a thickness of about 0.5 mm is attached to the coil rack. 104 Hole 125 That is, the present invention reduces the thickness of the water isolation sleeve 117 by a resin injection process. The present invention greatly reduces the gap between the armature 201 and the magnetic conductive inner sleeve, and increases the electromagnetic force acting on the armature 201 compared to the prior art water isolation sleeve having a thickness of 1.7 mm.

[0049] In the secondary resin injection, the male-threaded water isolation sleeve base 118 is also injection molded so that when assembling the water solenoid valve, the stator assembly 100 with integrated water isolation sleeve can be screwed into the female-threaded valve body 205 (see FIG. 11).

[0050] The magnetically conductive seat 121 is then mounted within the upper magnetically conductive inner sleeve 113 to form the resin encapsulated stator assembly shown in FIG.

[0051] 9a-9d show the structure of the upper and lower magnetic conductive inner sleeves of the present invention. The upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 of the present invention have a cylindrical shape, the wall of which is provided with a radial through hole 115 for passing adhesive, and the inner surface of the cylindrical wall is provided with a magnetic conductive inner sleeve axial groove 122 (for promoting the flow of hot molten resin during resin injection), which magnetic conductive inner sleeve axial groove 122 communicates with the radial through hole 115. The resin is injected into a coil rack having the upper and lower magnetic conductive inner sleeves. 104 Hole 125 By injecting into the water isolation sleeve 117The injected resin used to form the water isolation sleeve 117 flows into the magnetic conductive inner sleeve through hole 115 along the upper and lower magnetic conductive inner sleeve axial grooves 122 and forms a base for positioning the water isolation sleeve 117, thereby firmly fixing the water isolation sleeve 117 to the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 positioned by the magnetic conductive inner sleeve positioning ring 106.

[0052] In addition, the present invention may further provide a plurality of circumferential grooves (not shown) on the inner surfaces of the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 for further fixing the water isolation sleeve using radial grooves when the water isolation sleeve is resin sealed.

[0053] 12-14 show another embodiment of the present invention for forming a water isolation sleeve. First, the upper magnetic inner sleeve 113, the stopper 106, and the lower magnetic inner sleeve 114 are placed together (as shown in FIG. 12). Next, the upper magnetic inner sleeve 113, the stopper 106, and the lower magnetic inner sleeve 114 placed together are used as inserts for injecting resin to manufacture a water isolation sleeve assembly including a water isolation sleeve formed inside the upper magnetic inner sleeve and the lower magnetic inner sleeve (see FIG. 13 and FIG. 14). After that, the water isolation sleeve assembly is attached to the hole of the coil assembly, and resin is injected to form a resin-encapsulated stator assembly as shown in FIG. 4.

[0054] Compared with the technique of "injection molding the upper and lower magnetic conductive inner sleeves together with the water jacket and bobbin as an insert", the method of realizing the water-absorbing solenoid valve realized by the present invention can significantly reduce the working gap. This is because the water isolation sleeve of the present invention is formed by injecting resin into the hole of the coil rack, and a very thin water isolation sleeve can be formed. The technique of "injection molding the upper and lower magnetic conductive inner sleeves together with the water jacket and bobbin as an insert" is "injection molding the magnetic inner sleeve, the water jacket, and the coil rack into an integrated part", so the water jacket, the coil rack, and the magnetic inner sleeve need to be manufactured separately. Considering factors such as manufacturing process and strength, the water jacket must have a certain thickness that is greater than the thickness of the water isolation sleeve of the present invention in which resin is injected into the hole of the coil rack. Also, the technique of "injection molding the upper and lower magnetic conductive inner sleeves as inserts along with the water jacket and bobbin" is unable to include the yoke, coil windings, insert, coil rack, magnetic inner sleeve, and water isolation sleeve that form an integrated stator assembly.

[0055] The present invention also provides a water solenoid valve with increased electromagnetic attraction, manufactured according to the above-mentioned method, comprising a resin-encapsulated stator assembly and a valve body assembly including an armature, the valve body assembly being assembled together with the resin-encapsulated stator assembly to form a water solenoid valve. As shown in FIG. 3, the resin-encapsulated stator assembly of the present invention includes a coil assembly having a coil rack 104, a coil winding 109 wound around the coil rack 104, an insert 107, and electronic components 108 (see FIG. 5) mounted on the coil rack 104, an upper magnetic conductive inner sleeve 113 and a lower magnetic conductive inner sleeve 114 attached to holes in the coil assembly, a water isolation sleeve 117 disposed inside the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114, a yoke 111 disposed outside the coil assembly and connecting the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114, a magnetic conductive seat 121 attached inside the upper water isolation sleeve 117, and a resin encapsulation layer 116 covering the coil assembly and the yoke 111.

[0056] According to the present invention, the upper end surface of the movable core 201 in the initial position is higher than the upper edge of the lower magnetic conductive inner sleeve 114 and lower than 1 / 4 of the distance from the upper edge of the lower magnetic conductive inner sleeve 114 to the lower edge of the upper magnetic conductive inner sleeve 113, so that the electromagnetic attraction force of the water solenoid valve is increased.

[0057] Referring to FIG. 3, the valve body assembly of the water solenoid valve of the present invention includes a return spring 200 and an armature core 201 housed in a water isolation sleeve, a flow hole valve plug rubber 202, a valve plug 203, a valve plug rubber 204, a valve body 205, a mounting rack 206, a pressure relief ring 207, a rubber gasket 208, a filter screen assembly 209, etc.

[0058] According to the present invention, the upper end surface of the movable core in the initial position is higher than the upper edge of the lower magnetic conductive inner sleeve and lower than 1 / 4 of the distance from the upper edge of the lower magnetic conductive inner sleeve to the lower edge of the upper magnetic conductive inner sleeve, so that the electromagnetic attraction force of the water solenoid valve is strengthened.

[0059] According to the present invention, the length of the movable core in the lower magnetic conductive inner sleeve in the initial position is set to be equal to or greater than 1 / 4 of the sum of the height of the upper magnetic conductive inner sleeve and the height of the lower magnetic conductive inner sleeve, thereby ensuring that the magnetic conductivity of the non-working gap is not too small, avoiding the magnetic saturation of the iron core, and improving the resistance of the water solenoid valve to large impulse current impact.

[0060] The specific parameters for realizing the above-mentioned improvement of the magnetic circuit structure of the present invention include the following: the gap between the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve is 2mm-5mm, the diameter of the movable iron core is reduced from 6mm to 5±0.1mm, the inner diameter of the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve is 6.5±0.1mm, the wall thickness is 1mm, the outer diameter is 8.5±0.1mm, the inner diameter of the water isolation sleeve is 5.5±0.1mm, the outer diameter is 6.5±0.1mm, and the weight of the magnetic conductive seat is more than 60% of the weight of the movable iron core, which advantageously increases the magnetic conductivity, increases the electromagnetic attraction force, and strengthens the reliability of the valve suction.

[0061] Further, in accordance with the present invention, a water isolation sleeve is formed within the upper and lower magnetic conductive inner sleeves by injecting resin into the inner surfaces of the upper and lower magnetic inner sleeves.

[0062] Alternatively, the present invention can include placing the upper magnetic inner sleeve, the stopper, and the lower magnetic inner sleeve together as an insert and injection molding them to form a water isolation sleeve assembly. The water isolation sleeve assembly includes a water isolation sleeve that is mounted in a bore of the coil assembly and is formed by injection molding the inner surfaces of the upper magnetic inner sleeve and the lower magnetic inner sleeve.

[0063] On the other hand, the upper magnetic conductive inner sleeve 113 and the lower magnetic conductive inner sleeve 114 of the present invention have a cylindrical shape, and the wall is provided with a radial through hole 115 for passing adhesive. The inner surface of the wall is provided with a magnetic conductive inner sleeve axial groove 122, which communicates with the radial through hole 115. By injecting resin into the hole of the coil rack having the upper and lower magnetic conductive inner sleeves, the injected resin used to form the water isolation sleeve flows along the upper and lower magnetic conductive inner sleeve axial groove 122 into the magnetic conductive inner sleeve through hole 115, forming a base for placing the injection molded water isolation sleeve 117.

[0064] According to the experimental research of the present invention, the magnetic circuit structure of the water solenoid valve is designed to reduce consumption materials and reduce costs without adversely affecting the low pressure starting performance of the valve. The diameter of the movable iron core is reduced from 6mm to 5±0.1mm. The inner diameter of the water isolation sleeve is 5.5±0.1mm, the wall thickness is 0.5mm, and the outer diameter is 6.5±0.1mm. The inner diameter of the upper and lower magnetic conductive inner sleeves is 6.5±0.1mm, the wall thickness is 1mm, and the outer diameter is 8.5±0.1mm. The opening of the hole of the coil rack is about 8.7mm.

[0065] The water isolation sleeve vibrates under the action of the movable iron core during the operation of the valve, so the coil rack needs to meet certain rigidity requirements to avoid damage. According to the provisions of GB14536.1-2008 "Electrical automatic controllers for household and similar purposes" and GB4706.1-2005 "Safety of electrical appliances for household and similar purposes", the magnetic yoke of the water supply valve is exposed and is easily accessible to human hands. In order to meet the insulation requirements, the wall thickness of the skeleton must be 0.7mm or more. The magnetic yoke of the water supply valve of the present invention is resin-sealed and cannot be touched by human hands, and the skeleton does not have a thickness requirement and only needs to ensure the strength to prevent deformation during winding, so the thickness of the skeleton can be minimized.

[0066] The present invention adopts the manufacturing process of water isolation sleeve injection molding, so that the water isolation sleeve is formed by injecting resin into the stator assembly and is integrated with the coil rack, the wall thickness of the coil rack is not limited by the national standard, and the wall thickness of the coil rack hole is reduced from 1mm to 0.4mm, so that the coil diameter is further reduced, and the amount of copper wire is further reduced without changing the number of turns and wire diameter of the winding.

[0067] Furthermore, since the movable core is made smaller and lighter, when a voltage is applied to the coil winding 109, noise caused by the attractive force between the magnetized magnetic seat 121 and the movable core 201 is also reduced.

[0068] It should be noted that the injection molding process of the water isolation sleeve used in the water solenoid valve of this embodiment is merely one example of the manufacturing process of the water solenoid valve, and does not limit the magnetic circuit structure. The improvement method of the magnetic circuit structure of the present invention is effective for all water solenoid valves in strengthening the electromagnetic attraction force during starting, reducing the wire consumption, and reducing the noise caused by the moving iron core attraction, on the premise of meeting the minimum starting voltage requirement.

[0069] Although the present invention has been described in detail, the present invention is not limited thereto, and those skilled in the art may make various modifications based on the principles of the present invention. Therefore, modifications made based on the principles of the present invention are understood to fall within the scope of the present invention. [Explanation of symbols]

[0070] Stator assembly with water isolation sleeve 100; primary resin encapsulated stator assembly 101; stator assembly 102; coil assembly 103; coil rack 104; yoke locating bosses 105; magnetic conductive inner sleeve locating ring 106; insert 107; electronics 108; coil windings 109; yoke 111; yoke locating grooves 112; upper magnetic conductive inner sleeve 113; lower magnetic conductive inner sleeve 114; penetration hole-115;resin sealing layer-116;water isolation sleeve-117;water isolation sleeve base-118;water isolation sleeve inner cavity-119;magnetic conductive seat-121;magnetic conductive inner sleeve axial inner groove-122;magnetic conductive inner sleeve joint seam-123; 125-hole :Retractable spring-200;movable core-201;through hole plug rubber-202;valve plug 203;valve plug rubber-204;valve body 205;mounting rack-206;pressure relief ring-207;rubber gasket-208;filter screen assembly-209;flow hole-210;valve plug upper cavity-211;valve plug lower cavity-212;balance hole-213;water inlet-215;water outlet-216

Claims

1. A method for manufacturing a stator assembly with a water isolation sleeve for use in a water solenoid valve, comprising the steps of: placing an element including an insert (107) on a coil rack (104) having a hole (125) with a coil winding (109) wound thereon to form a coil assembly (103) having a hole (125); forming a stator assembly (102) by installing the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114) in a state in which the upper magnetic conductive inner sleeve (113) is inserted into an upper end of a hole (125) of the coil rack (104) of the coil assembly (103) and the lower magnetic conductive inner sleeve (114) is inserted into a lower end of the hole (125); and fixing a yoke (111) connecting the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114) to the outside of the stator assembly (102); injecting resin onto an outer surface of the stator assembly (102) to form a resin sealing layer (116) that covers the coil winding (109) and the yoke (111), thereby manufacturing a primary sealed resin sealed assembly (101); a step of injecting resin onto an inner surface of the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114) of the primary resin encapsulated assembly (101) to form a water isolation sleeve (117) on the inner surface of the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114), thereby manufacturing a stator assembly (100) including the water isolation sleeve (117).

2. A method for manufacturing a stator assembly as described in claim 1, wherein the hole (125) of the coil rack (104) is provided with a magnetically conductive inner sleeve positioning ring (106) for positioning the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114) at a predetermined distance inside the hole (125) of the coil rack (104).

3. A method for manufacturing a stator assembly as described in claim 2, comprising the step of simultaneously injecting resin into the primary sealed stator assembly (101) and forming a water isolation sleeve base (118) located at the lower end of the water isolation sleeve (117) for connecting and fixing a valve body assembly of a water solenoid valve.

4. A method for manufacturing a stator assembly with a water isolation sleeve for use in a water solenoid valve, comprising the steps of: forming a water isolation sleeve (117) by injecting resin onto an inner surface of the upper magnetic conductive inner sleeve (113), the magnetic conductive inner sleeve positioning ring (106), and the lower magnetic conductive inner sleeve (114) to form a water isolation sleeve assembly comprising the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114); placing an element including an insert (107) in a coil rack (104) having a hole (125) with a coil winding (109) wound therein, and fastening a yoke (111) connecting the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114) to the outside of the coil rack (104) to form a coil assembly (103); inserting the upper magnetically conductive inner sleeve (113), the magnetically conductive inner sleeve positioning ring (106), and portions of the lower magnetically conductive inner sleeve (114) of the water isolation sleeve assembly into holes (125) in a coil rack (104) of the coil assembly to form a stator assembly (102) including the water isolation sleeve, the upper magnetically conductive inner sleeve (113), the lower magnetically conductive inner sleeve (114), and the coil windings (109); A method for manufacturing a stator assembly (100) having a water isolation sleeve (117), comprising the steps of injecting resin onto an outer surface of the stator assembly (102) to form a resin encapsulation layer that covers coil windings and a yoke on the stator assembly (102).

5. A method for manufacturing a stator assembly as described in claim 4, wherein the water isolation sleeve assembly comprises: an upper magnetically conductive inner sleeve (113), a magnetically conductive inner sleeve positioning ring (106) and a lower magnetically conductive inner sleeve (114) fixed to each other by injection molding of resin; a water isolation sleeve (117) formed by injection molding of resin on the inner surfaces of the upper magnetically conductive inner sleeve (113), the magnetically conductive inner sleeve positioning ring (106) and the lower magnetically conductive inner sleeve (114); and a water isolation sleeve base (118) located at the lower end of the water isolation sleeve (117) and formed integrally with the water isolation sleeve (117).

6. A method for manufacturing a stator assembly described in any one of claims 1 to 5, wherein the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114) are each cylindrical, and their cylindrical walls are provided with radial through holes (115) through which air flows in.

7. A method for manufacturing a stator assembly as described in claim 6, wherein the inner surface of the upper magnetically conductive inner sleeve (113) and the inner surface of the lower magnetically conductive inner sleeve (114) are provided with an axial groove (122) communicating with the radial through hole (115).

8. A method for manufacturing a stator assembly as described in claim 7, wherein the inner surfaces of the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114) are provided with circumferential grooves communicating with the axial grooves (122).

9. A method for manufacturing a stator assembly as described in claim 8, wherein by injecting resin, a water isolation sleeve (117) and a water isolation sleeve base (118) are formed on the inner surfaces of the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114), and during the resin injection, the hot molten resin flows along the axial grooves (122) of the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114) into the radial through holes (115) of the magnetic conductive inner sleeves, forming a root for fixing the water isolation sleeve (117) and the resin sealing layer (116).

10. A stator assembly (100) for use in a water solenoid valve, comprising: A coil winding (109) is wound on a coil rack (104) having holes (125), and an insert (107) is placed on the coil rack (104); An upper magnetically conductive inner sleeve (113) is inserted into the upper end of the hole (125) of the coil rack (104); A lower magnetically conductive inner sleeve (114) is inserted into the lower end of the hole (125) of the coil rack (104); A resin injection molded water isolation sleeve (117) is provided along the inner surface of the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114); A yoke (111) is connected at its upper portion to an upper magnetically conductive inner sleeve (113) and at its lower portion to a lower magnetically conductive inner sleeve (114), a resin sealing layer (116) covering the coil assembly (103) and the yoke (111) while not covering a portion of the insert (107) electrically connected to an external power source, such that an upper portion of the yoke (111) is in intimate contact with an upper magnetically conductive inner sleeve (113) and a lower portion of the yoke (111) is in intimate contact with a lower magnetically conductive inner sleeve (114).

11. A stator assembly as described in Claim 10, wherein the lower end of the water isolation sleeve (117) is provided with a water isolation sleeve base (118) which is connected and fixed to the valve body (205) of the water solenoid valve and which is obtained by injection molding integrally with the water isolation sleeve (117), and the water isolation sleeve base (118) is not covered by the resin sealing layer (116).

12. A stator assembly as described in Claim 10, wherein the yoke (111) has yoke positioning grooves (112) on the top and bottom, the coil rack (104) has yoke positioning bosses (105) on its top and bottom end faces, and the yoke (111) is in a state where the yoke positioning bosses (105) of the coil rack (104) are clamped by the yoke positioning grooves (112) on the top and bottom.

13. A stator assembly as described in claim 10, wherein the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114) are cylindrical and include a water isolation sleeve fixing structure for attaching the water isolation sleeve (117) to the inner surfaces of the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114).

14. A stator assembly as described in Claim 13, wherein the water isolation sleeve fixing structure is a through hole (115) radially arranged in the upper magnetic conductive inner sleeve (113) and the lower magnetic conductive inner sleeve (114) that penetrate inside and outside the tube.

15. A stator assembly as described in claim 14, wherein the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114) have grooves on their inner surfaces facing the through hole (115).

16. A fixing assembly as described in claim 15, wherein the grooves include axial grooves (122) in the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114) communicating with a through hole (115).

17. A stator assembly as described in claim 16, wherein the grooves include circumferential grooves in the upper magnetically conductive inner sleeve (113) and the lower magnetically conductive inner sleeve (114) that communicate with the axial groove (122).

18. A water solenoid valve comprising a valve body assembly and a stator assembly having a water isolation sleeve (100) described in any one of claims 10 to 17, characterized in that the stator assembly having the water isolation sleeve (100) is assembled with the valve body assembly to form the water solenoid valve.

Images