Bobbin assembly

Abstract

A bobbin assembly for a solenoid assembly is disclosed herein. The bobbin assembly can include a cylindrical body portion, at least one flange portion, and at least one solder pad. The cylindrical body portion can extend along and be centered on an axis. The flange portion can extend radially outward, relative to the axis, and away from the cylindrical body portion. The flange portion can include an outer surface in a first plane normal to the axis and an inner surface in a second plane normal to the axis. The first plane and the second plane can be spaced from one another along the axis. The solder pad can be positioned on the flange portion and can have a pad surface that faces in a direction along the axis that is away from the inner surface. A method of processing the bobbin assembly is also disclosed herein.

Description

BOBBIN ASSEMBLYBACKGROUND1. Field

[0001] The present disclosure relates to switching devices of general application that are magnetically operated for use as a source of magnetic flux for performing external work.2. Description of Related Prior Art

[0002] U.S. Pat. No. 3331042 discloses an ENCAPSULATED ELECTROMAGNETIC ACTUATOR WITH THE ARMATURE THEREOF BEING COMPLETELY ENCLOSED. The ‘042 patent discloses an actuating magnet that has a magnet core surrounded by an excitation coil, and a housing formed of synthetic material, the magnet core and excitation coil being embedded in the housing.

[0003] U.S. Pat. No. 3609610 discloses a SOLENOID TERMINAL ASSEMBLY. The terminal assembly for a tubular solenoid includes a terminal cap having a pair of terminals secured thereto with openings therethrough which receive leads from the solenoid coil and may be attached to the terminals. An insulator is provided to coact with metal parts of the solenoid to enable the coil leads to be completely insulated therefrom.

[0004] U.S. Pat. No. 4041430 discloses a Coil Bobbin And Matching Cover For Solenoid Assembly. The improved bobbin and cover assembly is for use in the manufacture of an electrical solenoid includes internal centering lugs for the hollow core bobbin which position the solenoid core. Ridges are integrally molded in the end flange of the bobbin and cover for cooperation with a solenoid field assembly to provide insulation of the field assembly from the leads and to provide for centering of the field assembly.

[0005] U.S. Pat. No. 4217567 discloses a Tubular Solenoid. The ‘567 patent alleges that low cost tubular solenoids are formed with a drawn case in which the pole portion forming the base of the solenoid is defined as an integral inwardly extending part of the case. A coil bobbin is formed by the injection molding of plastic material and is provided with an integral wall which is positioned in abutting relation to the inside surface of the pole portion, thereby forming a stop surface for the solenoid plunger and effectively spacing the plunger from the base. The plunger is guided on the internal surfaces of the bobbin and in one embodiment, a spun hollow sheet metal bushing is captured by the case in telescopic relation to the bobbin, and is formed with threads which receive thereon a sheet metal retaining nut. In another embodiment of the invention, a washer is threaded onto an axialextension portion of the bobbin, and the open end of the case is crimped onto an annular groove formed on the washer. In a further embodiment, the washer is injected molded in place on the bobbin. Terminal leads are molded on the bobbin and extend through apertures formed in a bobbin extension eliminating the need for the placement of coil lead-in wires.

[0006] U.S. Pat. No. 6124775 discloses a Bobbinless Solenoid Coil. The bobbinless coil for a solenoid valve having at least one free standing wire termination. The turns of the coil winding are bound together by an adhesive coating. An end cap having at least one terminal post is adjacent to one end of the coil winding with the post receiving and supporting the free-standing wire termination. The terminal post and wire termination extend through an aperture formed though a ferro-magnetic flux casing which encloses the winding and end cap. A flux ring is disposed in an open end of the flux casing and secured thereto to retain the winding and end cap therein.

[0007] U.S. Pat. No. 6903647 discloses a Solenoid Valve Coil Having an Integrated Bobbin And Flux Ring Assembly. The coil assembly for a solenoid valve includes a bobbin formed from an electrically insulative material. A bore extends axially through the bobbin. A first flux ring having a sleeve extending axially from an annular base is mounted upon a first end of the bobbin with the sleeve extending into the bobbin bore. Similarly, a second flux ring also having a sleeve extending from an annular base is mounted upon a second end of the bobbin that is opposite from the first flux ring with its sleeve extending into the bobbin bore. The flux rings are formed from a magnetically permeable material that has a high heat conductivity. Magnet wire is wound upon the assembled bobbin and flux rings to form the coil assembly.

[0008] U.S. Pat. No. discloses a 10393908 a Bobbin Construction and Coil Winding Method. A bobbin for holding inductive coils includes features that yield a smaller overall size and prevent irregular and asymmetric coil windings. The bobbin comprises a central hub and a single flange that extends from a middle circumference of the hub. The bobbin includes no end flanges at the ends of the central hub, reducing the height of the bobbin. The interface between the flange and the hub is a sharp comer with little or no radius, facilitating regular and symmetrical coil geometries. Coil assemblies can be attached to the respective two sides of the flange concentrically with the hub. Each coil assembly can be formed by winding a transmitter coil, then winding a receiver coil concentrically over the transmitter coil. Conductive pins that extend from the outer edge of the flange interface the coil lead wires to a printed circuit board of an inductive sensor or other device.

[0009] The background description provided herein is for the purpose of generally presenting background context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwisequalify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.SUMMARY

[0010] This section provides a simplified summary in order to provide a basic understanding of some aspects described herein. This summary is not an extensive overview and is not intended to identify “key” or “critical” elements of the present disclosure or to delineate the scope of the various aspects described herein. The purpose of this portion of the document is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

[0011] A bobbin assembly for a solenoid assembly can include a cylindrical body portion, at least one flange portion, and at least one solder pad. The cylindrical body portion can extend along and can be centered on a first axis. The at least one flange portion can extend radially outward, relative to the first axis, and away from the cylindrical body portion. The at least one flange portion can include an outer surface in a first plane normal to the first axis and an inner surface in a second plane normal to the first axis. The first plane and the second plane can be spaced from one another along the first axis. The at least one solder pad can be positioned on the at least one flange portion and can have a pad surface that faces in a first direction along the first axis and away from the inner surface of the at least one flange portion.

[0012] According to other features, the pad surface of the at least one solder pad can be further defined as flush with the outer surface of the at least one flange portion. Alternatively, the pad surface of the at least one solder pad can be further defined as planar and in a third plane normal to the first axis and parallel to and spaced a first distance from the first plane, wherein the first distance is less than a thickness of the at least one flange portion along the first axis.

[0013] In other features, the at least one solder pad can be further defined as first and second solder pads. The first solder pad can be positioned on the at least one flange portion and can have a first pad surface that faces in the first direction along the first axis away from the inner surface of the at least one flange portion. The second solder pad can be positioned on the at least one flange portion and can have a second pad surface that faces in the first direction along the first axis away from the inner surface of the at least one flange portion. The second solder pad can be spaced from the first solder pad at least one of radially relative to the first axis and angularly about the first axis.

[0014] According to additional features, the second solder pad can be spaced from the first solder pad both radially relative to the first axis as well as angularly about the first axis. A radially- innermost portion of the first pad surface can be spaced a second distance from the first axis, aradially-innermost portion of the second pad surface can be spaced a third distance from the first axis, and the second distance can be different than the third distance. The bobbin assembly can also include a printed circuit board assembly including a printed circuit board and at least one terminal. The printed circuit board can be integral with the at least one flange portion and can include the first and second solder pads, a first trace extending away from the first solder pad, and a second trace extending away from the second solder pad. The at least one terminal can extend into the at least one flange portion and can be conductively connected to at least one of the first trace and the second trace. The printed circuit board can be disposed within a magnetic circuit that is defined when the bobbin assembly is operating as part of the solenoid assembly.

[0015] According to other features, the bobbin assembly can further include at least one tab releasably engaged with the at least one flange portion and thus configured to be removed from the at least one flange portion. The at least one tab can be integrally-formed with the at least one flange portion and at least one scoring line can be defined between the at least one tab and the at least one flange portion. Alternatively, the at least one tab and the at least one flange portion can be separately- formed. In such an embodiment, the at least one tab can include at least one first connector portion, the at least one flange portion can include at least one second connector portion, and the at least one first connector portion and the at least one second connector portion can directly engage one another to interconnect the at least one tab and the at least one flange portion. Neither the at least one first connector portion nor the at least one second connector portion need be damaged when disengaged from the other of the at least one first connector portion and the at least one second connector portion.

[0016] In other features, the at least one tab can further include a neck portion and a head portion. The neck portion can have a first thickness in a fourth plane. The head portion can be positioned at a first end of the neck portion and can have a second thickness in the fourth plane. The neck portion can be positioned between the head portion and the at least one flange portion. The first thickness in the fourth plane can be less than the second thickness in the fourth plane.

[0017] According to additional features, the at least one tab can project away from the at least one flange portion and can extend along and be centered on a second axis that is normal to the first axis. The at least one flange portion can include a radially-outermost edge that is at least substantially circular and the at least one tab can extend away from the radially-outermost edge. A maximum thickness of the at least one tab as defined along the first axis need not be greater than a maximum thickness the at least one flange portion as defined along the first axis.

[0018] According to other features, the at least one tab is further defined as first and second tabs. The first tab can be releasably engaged with the at least one flange portion and the second tabcan be releasably engaged with the at least one flange portion. The first tab can be spaced from the second tab at least one of radially relative to the first axis and angularly about the first axis.

[0019] In other features, the bobbin assembly can also include a coil, at least one slot, and at least one tab. The coil can include at least one wire wound around the cylindrical body portion and can define at least a first lead at a first end of the at least one wire and a second lead at a second end of the at least one wire opposite the first end of the at least one wire. The inner surface of the at least one flange portion can be positioned adjacent to the coil and can be between at least a majority of the coil and the outer surface of the at least one flange portion. The at least one slot can extend through the at least one flange portion radially outward relative to the first axis from a closed end to an open end and can also extend along the first axis between a third end at the inner surface of the at least one flange portion and fourth end at the outer surface of the at least one flange portion. The at least one tab can be releasably engaged with the at least one flange portion and thus configured to be removed from the at least one flange portion. The first lead can extend through the at least one slot through the third end and through the fourth end and can further extend across the at least one solder pad and can further encircle the at least one tab.

[0020] According to additional features, the at least one solder pad can be further defined as first and second solder pads. The first solder pad can positioned on the at least one flange portion and can have a first pad surface that faces in the first direction along the first axis away from the inner surface of the at least one flange portion. The second solder pad can be positioned on the at least one flange portion and can have a second pad surface that faces in the first direction along the first axis away from the inner surface of the at least one flange portion. The first lead can be further defined as extending across the first solder pad and soldered to the first solder pad. The second lead can extend through the at least one slot from the third end and through the fourth end and can further extend across the second solder pad and can be soldered to the second solder pad.

[0021] A method of processing the bobbin assembly disclosed above can include winding a first lead of a wire around a first tab that projects away from the at least one flange portion. The method can also include extending, after the winding, the first lead across the outer surface and across a first solder pad of the at least one solder pad. The method can also include soldering the first lead to the first solder pad. The method can also include directing, after the soldering, the first lead through a slot in the at least one flange portion from the outer surface toward the inner surface. The method can also include winding the wire into a coil around the cylindrical body portion. The method can also include directing, after the winding, a second lead of the wire through the slot in the at least one flange portion from the inner surface toward the outer surface. The method can also include extendingthe second lead across the outer surface and across a second solder pad of the at least one solder pad after the directing the second lead through the slot. The method can also include soldering the second lead to the second solder pad. The method can also include removing the first tab from the flange portion after the winding of the first lead around the first tab.

[0022] In other features, the method can also include winding the second lead of the wire around a second tab that projects away from the at least one flange portion after the soldering the second lead to the second solder pad. The method can also include removing the second tab from the flange portion after the winding of the second lead around the second tab.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The detailed description set forth below references the following drawings:

[0024] Figure 1 is a perspective view of a flange portion according to an exemplary embodiment of the present disclosure;

[0025] Figure 2 is a perspective view of a bobbin assembly according to an exemplary embodiment of the present disclosure;

[0026] Figure 3 is a perspective view of a processing method applied to the exemplary bobbin assembly according to an exemplary embodiment of the present disclosure;

[0027] Figure 4 is a perspective view of an exemplary wound bobbin assembly formed at least in part from the exemplary bobbin assembly shown in Figure 2;

[0028] Figure 5 is a perspective view of a solenoid assembly including the exemplary wound bobbin assembly shown in Figure 4;

[0029] Figure 6 is a partial cross-section through the flange portion along section lines 6 - 6 in Figure 2;

[0030] Figures 7A and 7B are partial cross-sections showing alternative connecting arrangements between a solder pad and a flange portion;

[0031] Figure 8 is front orthogonal view of the flange portion;

[0032] Figure 9 is detail view of an alternative embodiment of a connecting arrangement between a tab and the flange portion;

[0033] Figure 10 is a partial cross-section through the tab and the flange portion along section lines 10 - 10 in Figure 1;

[0034] Figure 11 is a first perspective view during a processing operation;

[0035] Figure 12 is a second perspective view during the processing operation; and

[0036] Figure 13 is a cross-section taken in a plane containing a centerline of the solenoid assembly while a current is being directed through a coil of the solenoid assembly.DETAILED DESCRIPTION

[0037] A plurality of different embodiments of the present disclosure is shown in the Figures of the application. Similar features are shown in the various embodiments of the present disclosure. Similar features across different embodiments have been numbered with a common reference numeral and have been differentiated by an alphabetic suffix. Also, to enhance consistency, the structures in any particular drawing share the same alphabetic suffix even if a particular feature is shown in less than all embodiments. Similar features are structured similarly, operate similarly, and / or have the same function unless otherwise indicated by the drawings or this specification. Furthermore, particular features of one embodiment can replace corresponding features in another embodiment or can supplement other embodiments unless otherwise indicated by the drawings or this specification.

[0038] The present disclosure, as demonstrated by the exemplary embodiments described below, can provide a compact design that can meet requirements from the overall package size in length and diameter. Further, the innovation disclosed herein obviates the need to insert terminals into a bobbin after the coil is wound or mold terminals into a bobbin in a way that does not ensure that insulation is properly displaced so that a solid long-lasting electrical connection is made. Further, the disclosure herein can leave a quite large connection at the back of a solenoid that far exceeds the current envelope.

[0039] An exemplary bobbin assembly 10 is shown in Figure 2 and Figure 1 shows subcomponents of the exemplary bobbin assembly 10. The exemplary bobbin assembly 10 is a component of an exemplary wound bobbin assembly shown in Figure 4 and the exemplary wound bobbin assembly is a component of an exemplary solenoid assembly 12 shown in Figure 5. The exemplary bobbin assembly 10 includes an exemplary cylindrical body portion 14, at least one exemplary flange portion 16, and at least one exemplary solder pad 18.

[0040] The exemplary cylindrical body portion 14 extends along and is centered on an exemplary first axis 20. The exemplary cylindrical body portion 14 includes an outer cylindrical surface 22 and an inner cylindrical surface 24. The exemplary cylindrical body portion 14 also includes a needle guide post 26 and one or more ramp protuberances, such as ramp protuberance 28, that project away from the outer cylindrical surface 22. The exemplary cylindrical body portion 14 also includes one or more stop protuberances, such as stop protuberance 30, projecting away from the inner cylindrical surface 24. The exemplary outer cylindrical surface 22, exemplary inner cylindricalsurface 24, exemplary needle guide post 26, exemplary ramp protuberances, and exemplary stop protuberances are integrally-formed. “Integrally-formed” is different than “integral” and refers to the fact that in the exemplary embodiment the exemplary outer cylindrical surface 22, exemplary inner cylindrical surface 24, exemplary needle guide post 26, exemplary ramp protuberances, and exemplary stop protuberances are formed together rather than being formed separately and then subsequently joined. The term “integrally-formed” defines a structural feature since structures that are integrally-formed are structurally different than structures that are comprised of subcomponents formed separately and then subsequently joined. “Integral” means consisting or composed of parts that together constitute a whole and thus encompasses structures of more than one part wherein the parts are either integrally-formed or formed separately and then subsequently joined.

[0041] The exemplary flange portion 16 extends radially outward, relative to the exemplary first axis 20, and away from the exemplary cylindrical body portion 14. The exemplary flange portion 16 includes an exemplary outer surface 32 in a first plane normal to the exemplary first axis 20 and an exemplary inner surface 34 in a second plane normal to the exemplary first axis 20. The exemplary first plane and the exemplary second plane are respectively referenced at 36 and 38 in Figure 6, which shows the exemplary first plane 36 and the exemplary second plane 38 spaced from one another along the exemplary first axis 20. It is noted that neither the outer surface 32 nor the inner surface 34 need be fully contained in a single plane in embodiments of the present disclosure.

[0042] The exemplary cylindrical body portion 14 also includes a second flange portion 40 and a third flange portion 42. The exemplary second and third flange portions 40, 42 are integrally- formed with exemplary outer cylindrical surface 22, exemplary inner cylindrical surface 24, exemplary needle guide post 26, exemplary ramp protuberances, and exemplary stop protuberances. In an exemplary approach to assembling the exemplary cylindrical body portion 14 and the exemplary flange portion 16, the exemplary cylindrical body portion 14 can be received in a central aperture 44 of the exemplary flange portion 16 and inserted until the exemplary flange portion 16 is captured between the ramp protuberances and the second flange portion 40. During assembly, the exemplary needle guide post 26 can pass through a slot 46 defined by the exemplary flange portion 16. It is noted that the central axis 20 passes through a center of the exemplary central aperture 44 when the bobbin assembly 10 is assembled.

[0043] The exemplary solder pad 18 is positioned on the exemplary flange portion 16 and has a exemplary pad surface 48 that faces in an exemplary first direction 50 along the exemplary first axis 20 and away from the exemplary inner surface 34 of the exemplary flange portion 16. The exemplary solder pad 18 is formed from a conductive material. The exemplary solder pad 18 is a relatively thinstructure. The exemplary solder pad 18 can be positioned on the exemplary outer surface 32 or can be embedded in the exemplary flange portion 16 and the exemplary pad surface 48 can be substantially flush with the exemplary outer surface 32.

[0044] Figures 7A and 7B are partial cross-sections through a flange and in a plane containing the central axis of a cylindrical body portion. Figure 7A shows an embodiment in which the exemplary solder pad 18a is positioned on the exemplary outer surface 32a of the flange portion 16a. The exemplary pad surface 48a is planar and in a third plane 52a that is normal to the exemplary first axis 20a and is also parallel to and spaced a first distance 54a from the exemplary first plane 36a. In the exemplary embodiment, the first distance 54a is less than a thickness 56a of the exemplary flange portion 16a along the exemplary first axis 20a. Figure 7B shows an embodiment in which the exemplary solder pad 18 is embedded in the exemplary flange portion 16. The exemplary pad surface 48 is flush with the exemplary outer surface 32 of the exemplary flange portion 16.

[0045] The exemplary bobbin assembly 10 also includes an exemplary second solder pad 58 positioned on the exemplary flange portion 16. The exemplary second solder pad 58 has an exemplary second pad surface 60 that faces in the exemplary first direction 50 along the exemplary first axis 20 away from the exemplary inner surface 34 of the exemplary flange portion 16. The exemplary second solder pad surface 58 is spaced from the first exemplary solder pad 18 at least one of radially relative to the exemplary first axis 20 and angularly about the exemplary first axis 20. The exemplary second solder pad 58 is spaced from the first exemplary solder pad 18 both radially relative to the exemplary first axis 20 as well as angularly about the exemplary first axis 20. This is best shown in Figure 8. A radially-innermost portion of the first exemplary pad surface 48 is spaced a second distance 62 from the exemplary first axis 20, a radially-innermost portion of the exemplary second pad surface 60 is spaced a third distance 64 from the exemplary first axis 20, and the second distance 62 is different than the third distance 64.

[0046] The exemplary bobbin assembly 10 also includes at least one tab 66 releasably engaged with the exemplary flange portion 16 and thus configured to be removed from the exemplary flange portion 16. The exemplary tab 66 can be utilized to tie-off a wire when a coil is formed on the exemplary cylindrical body portion 14, as set forth in greater detail below. “Releasably engageable” can be defined in several different ways. In one example, the exemplary tab 66 and exemplary flange portion 16 can be integrally-formed with respect to one another and the tab 66 can be intentionally- removeable from the exemplary flange portion 16 without damage to the exemplary flange portion 16. In such an embodiment, the exemplary tab 66 and the remainder of the exemplary flange portion 16 are initially fixed together as a result of being integrally-formed with respect to one another, butare subsequently separated. In such an embodiment, the exemplary flange portion can include score lines to facilitate removal of the tab 66 without damage to the remainder of the exemplary flange portion 16.

[0047] In another example, the exemplary tab 66 and the exemplary flange portion 16 are formed separately and subsequently joined through mating structures. Various mating structures could be utilized in various embodiments of the present disclosure, such as mating tongues and grooves, a projection in one of the exemplary tab 66 and the exemplary flange portion 16 and an aperture that receives the projection in the other of the exemplary tab 66 and the exemplary flange portion 16, or a relatively weak adhesive. Such mating structures can be themselves releasably engageable with respect to one another or one could be sacrificial (damaged upon separation from the other structure. It is noted that the exemplary tab 66 is not necessary for the operation of the exemplary solenoid assembly 12 for which the exemplary bobbin assembly 10 is a subcomponent.

[0048] Figure 9 shows an exemplary embodiment in which an exemplary tab 66b is integrally- formed with a remainder of an exemplary flange portion 16b. A scoring line 68b extends between the exemplary tab 66b and the exemplary flange portion 16b. The exemplary scoring line 68b can be defined by a plurality of small, discrete apertures arranged along the desired boundary between the exemplary tab 66b and the remainder of the exemplary flange portion 16b, grooves that extend along one or both of the inner and outer surfaces of the exemplary flange portion 16b at the desired boundary, or take some other form.

[0049] The exemplary tab 66 and exemplary flange portion 16 are separately -formed. The exemplary tab 66 includes at least one first connector portion. In this exemplary embodiment, the first connector portion includes tongues, such as the tongue referenced at 70 in Figure 8. The exemplary flange portion 16 includes at least one second connector portion. In this exemplary embodiment, the second connector portion includes grooves, such as the groove referenced at 72 in Figure 8. The exemplary first connector portion and the exemplary second connector portion directly engage one another to interconnect the exemplary tab 66 and the exemplary flange portion 16.

[0050] In the exemplary embodiment, the connector portion of mating tongues and grooves are themselves releasably engageable with respect to one another without damage to either connector portion. Other embodiments of the present disclosure could be practiced in which one of the connector portions is sacrificial and damaged when the connector portions are separated. For example, one of the connector portions could be defined by one or more apertures and the other connector portion could be defined by one or more stakes that are received in the apertures in a snap- fit engagement. The snap fit engagement would ensure that the exemplary tab 66 remains mountedon the exemplary flange portion 16 as long as desired. When it is desired to remove the exemplary tab 66 from the exemplary flange portion 16, the stakes could be broken whereby portions of the stake would remain in the apertures but the remainder of each stake would separate from apertures. Other possible approaches to connecting the exemplary tab 66 and the exemplary flange portion 16 in various embodiments of the present disclosure include adhesive formulated to have sufficient strength to hold the exemplary tab 66 as desired during manufacturing but to also permit separation of the tab 66 from the exemplary flange portion 16 when desired without damage to the exemplary flange portion 16.

[0051] The exemplary tab 66 includes a neck portion 74 and a head portion 76. The exemplary neck portion 74 has a first thickness 78 in a fourth plane, wherein the fourth plane in this example is the plane of view of Figure 8. The exemplary head portion 76 is positioned at a first end of the exemplary neck portion 74 and has a second thickness 80 in the fourth plane. The exemplary neck portion 74 is positioned between the exemplary head portion 76 and the exemplary flange portion 16. The exemplary first thickness 78 in the fourth plane is less than the exemplary second thickness 80 in the fourth plane. It is noted that in other embodiments of the present disclosure, a tab could be a post having a constant thickness.

[0052] The exemplary flange portion 16 includes a radially-outermost edge 82 that is at least substantially circular. The exemplary tab 66 extends away from the exemplary radially-outermost edge 82. The exemplary tab 66 projects away from the exemplary flange portion 16, extending along and centered on a second axis 84 that is normal to the exemplary first axis 20.

[0053] A maximum thickness 86 of the exemplary tab 66 as defined along the exemplary first axis 20 is not greater than a maximum thickness 88 the exemplary flange portion 16 as defined along the exemplary first axis 20, as shown in Figure 10. It is noted that the thicknesses 86, 88 of the exemplary tab 66 and the exemplary flange portion 16 as defined along the exemplary first axis 20 can vary as the distance from the first axis 20 changes in embodiments of the present disclosure, unlike the constant thicknesses shown in Figure 10.

[0054] The exemplary bobbin assembly 10 can also include a second tab 90 releasably engaged with the exemplary flange portion 16. The exemplary first tab 66 is spaced from the exemplary second tab 90 at least one of radially relative to the exemplary first axis 20 and angularly about the exemplary first axis 20.

[0055] The exemplary bobbin assembly 10 also includes a coil 92. The exemplary coil 92 includes a least one wire (referenced at 94) wound around the exemplary cylindrical body portion 14. The exemplary wire 94 defines at least a first lead 96 at a first end and a second lead 98 at a secondend opposite the first end. The exemplary inner surface 34 of the exemplary flange portion 16 is positioned adjacent the exemplary coil 92 and is between at least a majority of the exemplary coil 92 and the exemplary outer surface 32 of the exemplary flange portion 16. The exemplary coil 92 is position in between the exemplary flange portions 40 and 42.

[0056] The exemplary slot 46 extends through the exemplary flange portion 16 radially outward relative to the exemplary first axis 20 from a closed end that is closest to the first axis 20 to an open end that is closest to the first axis 20. The exemplary slot 46 also extends laterally, along the exemplary first axis 20, between a third end at the exemplary inner surface 34 of the exemplary flange portion 16 and fourth end at the exemplary outer surface 32 of the exemplary flange portion 16. The exemplary flange portion 40 has a similarly-shaped slot 100.

[0057] The exemplary first and second leads 96, 98 extend through the exemplary slots 46, 100. The exemplary first and second leads 96, 98 extend across the exemplary outer surface 32. The remainder and majority of the exemplary coil 92 is between the flange portions 40 and 42 and thus is spaced from the exemplary outer surface 32.

[0058] The exemplary first lead 96 extends across the first exemplary solder pad 18 and is soldered to the first exemplary solder pad 18 when the bobbin assembly 10 is acting as a component of the solenoid assembly 12. The exemplary second lead 98 extends across the exemplary second solder pad 58 and is soldered to the exemplary second solder pad 58 when the bobbin assembly 10 is acting as a component of the solenoid assembly 12.

[0059] The bobbin assembly 10 can also include one or more circuit components. The exemplary bobbin assembly 10 includes a printed circuit board assembly (PCBA), referenced generally at 124 in Figure 1. The exemplary PCBA 124 includes a printed circuit board (PCB) 126, a transient suppressor 102, and terminals 128, 130. The exemplary PCB 126 is integral with the flange portion 16 and includes the first solder pad 18, a first trace 104 extending away from the first solder pad 18, the second solder pad 58, a second trace 108 extending away from the second solder pad 58 and extending to the terminal 130, and a third trace 106. The exemplary third trace 106 extends away from the transient suppressor 102 and extends to the terminal 128. The exemplary third trace 106 is conductively connected with both the transient suppressor 102 and with the terminal 128. The exemplary second trace 108 is conductively connected to the terminal 130. The exemplary transient suppressor 102 can to prevent over-voltages and dissipate high transient power surges and is mounted on the exemplary flange portion 16. The exemplary bobbin assembly 10 also includes a terminal boss 110 in which the terminals 128 and 130 are at least partially surrounded and protected. The exemplaryPCB 126 is disposed within a magnetic circuit defined when current is directed through the coil 92, as shown in Figure 13.

[0060] The exemplary terminals 128, 130 extend into the flange portion 16 for enhanced rigidity and can be disposed in situ with respect to the flange portion 16. “In situ” refers to an aspect of structure that the flange portion 16, in one or more embodiments, is integral with, at least partially surrounds, and precisely conforms to a portion of the outer surface of each terminal 128, 130 such that neither terminal 128, 130 can be removed from the flange portion 16 without deforming or breaking the flange portion 16 in such embodiments. For example, the terminals 128, 130 can be placed in a cavity of a mold, held in place by the structure(s) defining the cavity of the mold and material which forms the flange portion 16 can be dispensed in non-solid form in the mold and flow around the terminals 128, 130 The flange portion 16 then cools and hardens or sets around the portions of the terminals 128, 130. In situ is the structural aspect of the engagement between the two parts and the casting or molding operation is the method applied to arrive at the structural aspect.

[0061] A method of processing the exemplary bobbin assembly 10 can include actions for adding the coil 92 to the exemplary cylindrical body portion 14 and the exemplary flange portion 16a. A distal end of the exemplary first lead 96 can be grasped and help by a gripper, illustrated schematically in Figure 11 and referenced by 112. Next, a magnet wire position control needle 114 can wind the exemplary first lead 96 of the exemplary wire 94 around the first tab 66.

[0062] The magnet wire position control needle 114 can then extend the exemplary first lead 96 across the exemplary outer surface 32 and across a first exemplary solder pad 18. The first lead 96 can then be soldered to the first exemplary solder pad 18. The gripper 112 can then release the exemplary wire 94. The magnet wire position control needle 114 can then be moved through slots 46, 100, toward the exemplary inner surface 34. The exemplary cylindrical body portion 14 can then be rotated and the magnet wire position control needle 114 can be moved back and forth between the flange portions 40, 42 to wind the exemplary wire 94 into the exemplary coil 92 around the exemplary cylindrical body portion 14.

[0063] Subsequent to the formation of the exemplary coil 92, the magnet wire position control needle 114 can be moved back through the exemplary slots 46, 100 to direct the exemplary second lead 98 of the exemplary wire 94 through the slots 46, 100 from the exemplary inner surface 34 toward the exemplary outer surface 32. The exemplary second lead 98 is extended across the exemplary outer surface 32 and across the exemplary second solder pad 58. The exemplary second lead 98 can then be soldered to the exemplary second solder pad 58.

[0064] The processing can continue by controlling the magnet wire position control needle 114 to wind the exemplary second lead 98 of the exemplary wire 94 around the second tab 90, as shown in Figure 12. Next, the portion of the exemplary first lead 96 beyond the solder pad 18 can be cut, the portion of the exemplary second lead 98 beyond the solder pad 58 can be cut, and the exemplary tabs 66 and 90 can be removed from the exemplary flange portion 16, as shown in Figure4. The exemplary tabs 66 and 90 are removed from the exemplary flange portion 16 without damaging the exemplary flange portion 16.

[0065] The processing can continue by inserting the exemplary wound bobbin assembly, as shown in Figure 4, in an outer casing 116 of the exemplary solenoid assembly 12 as shown in Figure5. A spring (not shown) and piston 118 of the exemplary solenoid assembly 12 can be inserted in the exemplary cylindrical body portion 14. An end cap 120 of the exemplary solenoid assembly 12 can be engaged with an end of the exemplary outer casing 116 to substantially enclose the exemplary bobbin assembly 10. The exemplary solenoid assembly 12 can include other components positioned within and / or outside the outer casing 116 as well. The exemplary end cap 120 can include a notch 122 so that the terminal boss 110 is exposed on an exterior of the exemplary solenoid assembly 12 and thus available for connection to a power source.

[0066] What has been described above includes examples of the subject innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the disclosed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the subject innovation are possible. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to be illustrative and does not pose a limitation on the scope of any invention disclosed herein unless otherwise claimed. The word “exemplary” is used to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion.

[0067] As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Unless indicated otherwise by context, the term “or” is to be understood as an inclusive “or.” Terms such as “first”, “second”, “third”, etc. when used to describe multiple devices or elements, are so used only to convey the relative actions, positioning and / or functions of the separate devices, and do not necessitate either a specific order for such devices or elements, or any specific quantity or ranking of such devices or elements. Any use of the terms“about” or “approximately” are intended to describe values above and / or below a stated value or range, as would be understood by one having ordinary skill in the art in the respective context.

[0068] It will be understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof, unless indicated herein or otherwise clearly contradicted by context. Any recitations of a value range herein, unless indicated otherwise, serves as a shorthand for referring individually to each separate value falling within the stated range, including the endpoints of the range, each separate value within the range, and all intermediate ranges subsumed by the overall range, with each incorporated into the specification as if individually recited herein. Unless indicated otherwise, or clearly contradicted by context, methods described herein can be performed with the individual steps executed in any suitable order, including: the precise order disclosed, without any intermediate steps or with one or more further steps interposed between the disclosed steps; with the disclosed steps performed in an order other than the exact order disclosed; with one or more steps performed simultaneously; and with one or more disclosed steps omitted.

[0069] While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to a particular embodiment disclosed herein as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will be viewed as covering any embodiment falling within the scope of the appended claims. Various aspects or features described herein may be implemented as a method, apparatus, or article of manufacture using standard programming and / or engineering techniques.

[0070] Also, the right to claim a particular sub-feature, sub-component, or sub-element of any disclosed embodiment, singularly or in one or more sub-combinations with any other sub-feature(s), sub-component(s), or sub-element(s), is hereby unconditionally reserved by the Applicant. Also, a particular sub-feature(s), sub-component(s), and sub-element(s) of one embodiment that is disclosed herein can replace a particular sub-feature(s), sub-component(s), and sub-element(s) in another embodiment disclosed herein or can supplement and be added to other embodiments unless otherwise indicated by the drawings or this specification. For example, at this time the tie-off tabs disclosed herein and each attribute thereof are viewed by the Applicant as innovations distinct from the solderpads. The method of manufacturing disclosed herein is viewed by the Applicant at this time as an invention distinct from the structures assembled in the method. The inventors also assert that any of the claims set forth after this detailed description can be combined with any other claim or claims regardless of whether or not there is a direct line of dependency, unless there is an express indication in this text or the drawings unambiguously indicating that such a combination is not possible. The order of the claims and the lines of dependency are irrelevant to the various ways that the features, elements, sub-elements, components, sub-components, etc. of the present disclosure can be combined and thus claimed. Further, the use of the word “can” in this document is not an assertion that the subject preceding the word is unimportant or unnecessary or “not critical” relative to anything else in this document. The word “can” is used herein in a positive and affirming sense and no other motive should be presumed. More than one “invention” may be disclosed in the present disclosure; an “invention” is defined by the content of a patent claim and not by the content of a detailed description of an embodiment of an invention.

Claims

CLAIMSWhat is claimed is:

1. A bobbin assembly for a solenoid assembly comprising: a cylindrical body portion extending along and centered on a first axis; at least one flange portion extending radially outward, relative to said first axis, and away from said cylindrical body portion, said at least one flange portion including an outer surface in a first plane normal to said first axis and an inner surface in a second plane normal to said first axis, said first plane and said second plane spaced from one another along said first axis; and at least one solder pad positioned on said at least one flange portion and having a pad surface that faces in a first direction along said first axis and away from said inner surface of said at least one flange portion.

2. The bobbin assembly of claim 1 wherein said pad surface of said at least one solder pad is further defined as flush with said outer surface of said at least one flange portion.

3. The bobbin assembly of claim 1 wherein said pad surface of said at least one solder pad is further defined as planar and in a third plane normal to said first axis and parallel to and spaced a first distance from said first plane, wherein said first distance is less than a thickness of said at least one flange portion along said first axis.

4. The bobbin assembly of claim 1 wherein said at least one solder pad is further defined as: a first solder pad positioned on said at least one flange portion and having a first pad surface that faces in said first direction along said first axis away from said inner surface of said at least one flange portion; a second solder pad positioned on said at least one flange portion and having a second pad surface that faces in said first direction along said first axis away from said inner surface of said at least one flange portion; and wherein said second solder pad is spaced from said first solder pad at least one of radially relative to said first axis and angularly about said first axis.

5. The bobbin assembly of claim 4 wherein said second solder pad is spaced from said first solder pad both radially relative to said first axis as well as angularly about said first axis.

6. The bobbin assembly of claim 4 wherein a radially-innermost portion of said first pad surface is spaced a second distance from said first axis, a radially-innermost portion of said second pad surface is spaced a third distance from said first axis, and said second distance is different than said third distance.

7. The bobbin assembly of claim 4 further comprising a printed circuit board assembly including: a printed circuit board integral with said at least one flange portion and including: said first solder pad, a first trace extending away from said first solder pad, said second solder pad, and a second trace extending away from said second solder pad; and at least one terminal extending into said at least one flange portion and conductively connected to at least one of said first trace and said second trace.

8. The bobbin assembly of claim 1 further comprising: at least one tab releasably engaged with said at least one flange portion and thus configured to be removed from said at least one flange portion.

9. The bobbin assembly of claim 8 wherein said at least one tab is further defined as integrally-formed with said at least one flange portion.

10. The bobbin assembly of claim 9 further comprising: at least one scoring line between said at least one tab and said at least one flange portion.

11. The bobbin assembly of claim 8 wherein said at least one tab and said at least one flange portion are further defined as separately-formed, wherein said at least one tab includes at least one first connector portion, wherein said at least one flange portion includes at least one secondconnector portion, and wherein said at least one first connector portion and said at least one second connector portion directly engage one another to interconnect said at least one tab and said at least one flange portion.

12. The bobbin assembly of claim 11 wherein neither said at least one first connector portion nor said at least one second connector portion is damaged when disengaged from the other of said at least one first connector portion and said at least one second connector portion.

13. The bobbin assembly of claim 8 wherein said at least one tab further comprises: a neck portion having a first thickness in a fourth plane; a head portion positioned at a first end of said neck portion and having a second thickness in the fourth plane; and wherein said neck portion is positioned between said head portion and said at least one flange portion and wherein said first thickness in the fourth plane is less than said second thickness in the fourth plane.

14. The bobbin assembly of claim 8 wherein said at least one tab projects away from said at least one flange portion, extending along and centered on a second axis that is normal to said first axis.

15. The bobbin assembly of claim 8 wherein said at least one flange portion includes a radially-outermost edge that is at least substantially circular and said at least one tab extends away from said radially-outermost edge.

16. The bobbin assembly of claim 8 wherein a maximum thickness of said at least one tab as defined along said first axis is not greater than a maximum thickness said at least one flange portion as defined along said first axis.

17. The bobbin assembly of claim 8 wherein said at least one tab is further defined as: a first tab releasably engaged with said at least one flange portion; a second tab releasably engaged with said at least one flange portion; andwherein said first tab is spaced from said second tab at least one of radially relative to said first axis and angularly about said first axis.

18. A wound bobbin assembly comprising: a cylindrical body portion extending along and centered on a first axis; at least one flange portion extending radially outward, relative to said first axis, and away from said cylindrical body portion, said at least one flange portion including an outer surface in a first plane normal to said first axis and an inner surface in a second plane normal to said first axis, said first plane and said second plane spaced from one another along said first axis; at least one solder pad positioned on said at least one flange portion and having a pad surface that faces in a first direction along said first axis and away from said inner surface of said at least one flange portion; a coil including at least one wire wound around said cylindrical body portion and defining at least a first lead at a first end of said at least one wire and a second lead at a second end of said at least one wire opposite said first end of said at least one wire, said inner surface of said at least one flange portion positioned adjacent said coil and between at least a majority of said coil and said outer surface of said at least one flange portion; at least one slot extending through said at least one flange portion radially outward relative to said first axis from a closed end to an open end, said at least one slot also extending along said first axis between a third end at said inner surface of said at least one flange portion and fourth end at said outer surface of said at least one flange portion; at least one tab releasably engaged with said at least one flange portion and thus configured to be removed from said at least one flange portion; and wherein said first lead extends through said at least one slot through said third end and through said fourth end and further extends across said at least one solder pad and further encircles said at least one tab.

19. The bobbin assembly of claim 18 wherein: said at least one solder pad is further defined as: a first solder pad positioned on said at least one flange portion and having a first pad surface that faces in said first direction along said first axis away from said inner surface of said at least one flange portion; a second solder pad positioned on said at least one flange portion and having a second pad surface that faces in said first direction along said first axis away from said inner surface of said at least one flange portion; said first lead is further defined as extending across said first solder pad and soldered to said first solder pad; and wherein said second lead extends through said at least one slot from said third end and through said fourth end and further extends across said second solder pad and is soldered to said second solder pad.

20. The bobbin assembly of claim 19 further comprising a printed circuit board assembly including: a printed circuit board integral with said at least one flange portion and including: said first solder pad, a first trace extending away from said first solder pad, said second solder pad, and a second trace extending away from said second solder pad, wherein said printed circuit board is disposed within a magnetic circuit defined when current is directed through said coil; a first terminal extending into said at least one flange portion and conductively connected to said first trace; and a second terminal extending into said at least one flange portion and conductively connected to said second trace.

21. A method of processing the bobbin assembly set forth in claim 1 comprising: winding a first lead of a wire around a first tab that projects away from the at least one flange portion; extending, after said winding, the first lead across the outer surface and across a first solder pad of the at least one solder pad; soldering the first lead to the first solder pad; directing, after said soldering, the first lead through a slot in the at least one flange portion from the outer surface toward the inner surface; winding the wire into a coil around the cylindrical body portion; directing, after said winding, a second lead of the wire through the slot in the at least one flange portion from the inner surface toward the outer surface; extending the second lead across the outer surface and across a second solder pad of the at least one solder pad after said directing the second lead through the slot; soldering the second lead to the second solder pad; and removing the first tab from the flange portion after said winding the first lead around the first tab.

22. The method of claim 21 further comprising: winding the second lead of the wire around a second tab that projects away from the at least one flange portion after said soldering the second lead to the second solder pad; and removing the second tab from the flange portion after said winding the second lead around the second tab.

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