A non-binding solenoid system

Abstract

A non-binding solenoid system may have a coil that is located in a coil housing unit. The non-binding solenoid system may also have an armature that has a plurality of surfaces and an upper and lower portion. An armature relief portion may be located in either the inboard portion of the coil housing unit or the upper portion of the armature, and the armature relief portion may be adapted to allow the armature to rotate with respect to the coil housing unit.

Description

[0001] TITLE

[0002] A NON-BINDING SOLENOID SYSTEM

[0003] FIELD

[0004] A device that relates to a non-binding solenoid system is depicted and described.

[0005] BACKGROUND

[0006] Solenoids often require good alignment with parts they are imparting motion to. In some cases, the components of the solenoid might not be aligned or ideally suited for the application and / or the parts they are imparting motion to might not be aligned with the solenoid. If the alignment is not good, components of the solenoid and / or their imparted motion parts may move, such as tilt, and then stick. When these solenoids and / or their imparted motion parts stick the resulting motion may be jerky or they may not move at all.

[0007] In view of the disadvantages associated with the prior art designs, it would be advantageous for a solenoid to have a design that ensures the solenoid doesn’t stick and / or if the part the solenoid is imparting motion to is not property aligned, the solenoid can adapt to the misalignment to ensure a smooth movement.

[0008] SUMMARY

[0009] In one aspect, a non-binding solenoid system may have a coil that is located in a coil housing unit. The system may also have an armature that has a plurality of surfaces and an upper and lower portion. An armature relief portion may be located in either the inboard portion of the coil housing unit or the upper portion of the armature, and the armature relief portion is adapted to allow the armature to rotate with respect to the coil housing unit.

[0010] In another aspect, two of the plurality of surfaces may be directly connecting and perpendicular to one another.

[0011] In another aspect, the directly connecting and perpendicular surfaces may be adapted to receive a transfer ring.

[0012] In another aspect, the armature relief portion may have a first angled surface, a middle surface, and a second angled surface.

[0013] In another aspect, the first angled surface and the second angled surface may be angled equally towards one another, and the middle surface may be centered between the first angled surface and the second angled surface.

[0014] In another aspect, the middle surface is cylindrical and adapted to make slidable contact with the inboard portion of the coil housing unit.

[0015] In another aspect, the first angled surface and the second angled surface may be adapted to enter gaps between the coil housing unit and the armature.

[0016] In another aspect, the armature relief portion may have an arced surface that is adapted to make slidable contact with the inboard portion of the coil housing unit.

[0017] In another aspect, the armature relief portion may may have a level surface that is adapted to make slidable contact with the inboard portion of the coil housing unit. In another aspect, the inboard portion of the coil housing unit may have a surface that is conically shaped.

[0018] In another aspect, the inboard portion of the coil housing unit may at least partially enclose the coil.

[0019] In another aspect, the armature may be one piece, integrally formed, and unitary.

[0020] In another aspect, the upper portion of the armature may have a protruding portion.

[0021] In another aspect, the protruding portion may be adapted to have a complementary shape to a portion of the coil housing unit with which the protruding portion is in selective contact.

[0022] In another aspect, the protruding portion may be tapered at an angle that is complementary to an angle of the portion of the coil housing unit with which the protruding portion is in selective contact.

[0023] BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Fig. 1 is a cut-away side view of one embodiment of a portion of a solenoid system;

[0025] Fig. 2 is a cut-away side view of the solenoid system of Fig. 1 depicting tilt of certain components;

[0026] Fig. 3 is a cut-away side view of a portion of another embodiment of a solenoid system; and Fig. 4 is a cut-away side view of a portion of another embodiment of a solenoid system.

[0027] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] It is to be understood that the device and processes may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the concepts. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise.

[0029] T urning now to Fig. 1 , one embodiment of a solenoid system 10 is depicted. Fig. 1 also depicts an x-y coordinate system. In this instance, the x direction will be associated with lateral inboard (negative x) and lateral outboard (positive x) directions. The y direction will be associated with radial inboard (negative y) and outboard (positive y) directions.

[0030] The system 10 may be ring shaped and may comprise an upper portion 10a and a lower portion 10b, as shown in Fig. 2. The upper portion 10a and the lower portion 10b may be substantially similar to one another. In other words, the upper portion 10a and the lower portion 10b may be mirror images of one another. As such, only one portion will be described herein. The system 10 may comprise a coil 12 capable of being selectively electrified and generating a magnetic flux. The coil 12 may be located in a coil housing 14. The housing 14 may be a one-piece design or it may be comprised of two or more pieces. One aspect of the housing 14 may be such as a radial inboard portion 16 that may be located at least partially radially inboard of the coil 12. The radial inboard portion 16 may have a cross-sectional shape that is generally L-shaped where the two legs of the L shape may at least partially enclose the coil 12. The radial inboard portion 16 may be fixed in its position.

[0031] In one embodiment, a radial inboard innermost surface 18 of the housing 14 may be substantially parallel to the x-axis. This surface 18 may be directly adjacent to and may be in selective direct contact with an armature 20.

[0032] The armature 20 may be adapted for selective movement with respect to the coil housing 14. The movement may be caused by the magnetic flux that selectively extends from the coil 12 into the armature 20. The armature 20 may be provided with a plurality of surfaces 22-32, 46, 48, 54, 56, 60, 62. One, some or all of the surfaces 22-32, 46, 48, 54, 60, 62 may assist the armature 20 in bind-free movement with respect to the coil housing 14. The surfaces 22-32, 46, 48, 54, 60, 62 may define a perimeter of the armature 20. While a number of surfaces are described below, the armature 20 may have any number of surfaces oriented as noted below or in a different orientation. The armature 20 may be one piece, integrally formed and unitary.

[0033] One surface may be such as a first radially extending surface 22. This first surface 22 may extend generally transverse the x-axis. It may be the most laterally outboard surface of the armature 20. The armature 20 may also be comprised of a second surface 24. The second surface 24 may be such as a laterally extending surface. The second surface 24 may be directly connected to the first surface 22. The second surface 24 may extend generally parallel the x-axis and it may extend generally perpendicular to the first surface 22.

[0034] The armature 20 may also be comprised of a third surface 26. The third surface 26 may be such as an angled surface. The third surface 26 may be directly connected to the second surface 24. The third surface 26 may extend in both the lateral and radial directions as it creates an angled transition directly from the second surface 24 to a fourth surface 28.

[0035] The fourth surface 28 may also be part of the surfaces 22-32, 46, 48, 54, 56, 60, 62 defining the armature 20 perimeter. The fourth surface 28 may be such as a laterally extending surface that directly connects with the third surface 26. The fourth surface 28 may extend generally parallel the x-axis. The fourth surface 28 may be the innermost radial surface of the armature 20.

[0036] The fourth surface 28 may transition directly to a fifth surface 30. The fifth surface 30 may extend in a generally radial direction from the fourth surface 28. The radial direction may be such as generally transverse the x-axis. The fifth surface 30 may extend in the radial outboard direction until it reaches a sixth surface 32.

[0037] The sixth surface 32 may extend in the lateral inboard direction away from the intersection with the fifth surface 30. The sixth surface 32 may extend generally parallel the x-axis and at a radial distance that may be generally equal to the second surface 24. In other words, in some embodiments, the sixth surface 32 may be generally parallel and coplanar with the second surface 24.

[0038] The fifth surface 30 and the sixth surface 32 may be oriented generally transverse one another. In some cases, they may form, or define, an area to receive a portion of a transfer ring 34 therein.

[0039] In some embodiments, the transfer ring 34 may have an L-shaped crosssection. The L-shape may have a first leg 36 that generally extends in the lateral direction and may be parallel the x-axis. The L-shape may have a second leg 38 directly connected to the first leg 36. The second leg 38 may generally extend in the radial direction. Movement associated with the armature 20 may be directly transferred to the transfer ring 34, such as from / through the fifth surface 30 and / or sixth surface 32 to the first leg 36. The transfer ring 34 may be connected to one or more other components to push and / or pull those components.

[0040] In some cases, the first leg 36 may have an armature foot 40. The armature foot 40 may have a radial height the same or similar to the fifth surface 30. The armature foot 40 may have a lateral length that is at least as long as the sixth surface 32.

[0041] Laterally inboard of the armature foot 40 the first leg 36 may have a recessed portion 42. The recessed portion 42 may radially extend into the first leg 36 so as to reduce its radial thickness. The recessed portion 42 may be adapted to selectively receive a portion 44 of the coil housing 14 therein during movement of the armature 20, which may be seen in Fig. 2. The recessed portion 42 may be adapted in size, shape and / or location to accommodate the coil housing portion 44 as needed. While the transfer ring 34 is mentioned, a transfer ring 34 is not required. It may be the case that the armature 20 alone may accommodate lateral and tilt movements.

[0042] Fig. 2 also depicts one condition in which the transfer ring 34 is tilted with respect to the x-axis. The armature 20, being connected to the transfer ring 34, also tilts the same or similar amount. The armature 20 and transfer ring 34 herein are adapted to accommodate such tilt and still provide the required or needed push and / or pull motion to the transfer ring 34.

[0043] The sixth surface 32 may directly transition to a seventh surface 46. In some cases, the seventh surface 46 may be such as a radially extending surface such as in a generally transverse direction to the x-axis. The seventh surface 46 may have a radial extension that is less than the radial extension of the first surface 22. The seventh surface 46 may also be the most lateral inboard surface of the armature 20.

[0044] The seventh surface 46 may directly transition to an eighth surface 48. The eighth surface 48 may extend in both the lateral and radial directions at an angle. The eighth surface 48 may have a lateral extension that locates a lateral end 48a further laterally outboard than the fifth surface 30. The eighth surface 48, in combination with the sixth surface 32, may create a tapered laterally inboard section 50 for the armature 20 that terminates in the seventh surface 46.

[0045] In some cases, the seventh surface 46 and eighth surface 48 may have a complementary shape with a portion of the coil housing 14. The seventh surface 46 and eighth surface 48 may be adapted to meet with, and stop against, complementary shaped surfaces 52 of the coil housing 14 upon selective generally lateral movement of the armature 20.

[0046] The eighth surface 48 may directly transition to a ninth surface 54. The ninth surface 54 may be such as a generally radially inboard extending surface. It may be that the ninth surface 54 extends generally transverse the x-axis.

[0047] The ninth surface 54 may directly transition to a tenth surface 56 that may be an inboard armature relief portion 56. The inboard armature relief portion 56 may be such as a conical feature formed in the armature 20. The tenth surface 56 may extend into the armature 20 at a predetermined angle 58. For example, the extent to which the tenth surface 56 extends into the armature 20 may be the same or similar to an angle at which the armature 20 may tilt during actuation. The tenth surface 56 may extend into the armature 20 at an angle in both a radial and a lateral direction. While the ninth surface 54 and eighth surface 48 are described, in another embodiment, it may be the case that the tenth surface 56 extends directly to the seventh surface 46. In other words, this embodiment may have an armature 20 that does not comprise surface 54 and surface 48.

[0048] The tenth surface 56 may directly transition to an eleventh surface 60, which may be a cylindrical section of the armature 20. The eleventh surface 60 may be the outermost surface in the radial outboard direction for the armature 20. The eleventh surface 60 may at least partially radially overlap the fourth surface 28. The eleventh surface 60 may be adapted to be the primary guide, or pilot, of the armature 20 along its generally lateral motion along the radially inboard innermost surface 18 of the radial inboard portion 16 of the coil housing 14. In some cases, it may be preferred for the eleventh surface 60 to have a lateral dimension as long as possible. In some cases, however, the lateral dimension is limited by the radial clearance that will accommodate a tilt of the armature 20. The eleventh surface 60 may be at least partially centered between the tenth surface 56 and a twelfth surface 62.

[0049] The eleventh surface 60 may directly transition to the twelfth surface 62 which may be an outboard armature relief portion 62. The outboard armature relief portion 62 may be such as a conical feature formed in the armature 20. The twelfth surface 62 may extend into the armature 20 at a predetermined angle 64. For example, the extent to which the twelfth surface 62 may extend into the armature 20 may be the same or similar to an angle at which the armature 20 may tilt during actuation. The twelfth surface 62 may extend into the armature 20 at an angle in both a radial and lateral direction. The twelfth surface 62 may directly transition to the first surface 22.

[0050] In some embodiments, the angle at which the tenth surface 56 and twelfth surface 62 extend into the armature 20 may be the same or similar to the angle the armature 20 may be tilted. For example, if it is desired to permit the armature 20 to tilt approximately 1 degree, each of the angles may be the same or similar to approximately 1 degree (such as 1 degree measured from below the horizontal).

[0051] From the foregoing, it may be appreciated that the tenth surface 56, eleventh surface 60, and twelfth surface 62 may be designed to accommodate misaligned armature 20 components, misaligned parts acted upon by the armature 20 and / or misalignment between the armature 20 and the acted upon parts. For example, the armature 20 may tilt which may also be considered a pivot or rotation to accommodate any of the foregoing misalignment and the armature 20 will still work as intended in a smooth manner.

[0052] Turning now to Fig. 3, another embodiment is schematically depicted. The embodiment may have the same coil housing 14 design as noted above. And, the armature 20 may have a similar design to that described above and depicted in Fig. 1 . One difference between the armature 20 design in Fig. 1 and this design is that this design may remove the cylindrical section located between the tenth surface 56 and twelfth surface 62. Instead, the surface 66 extending from the first surface 22 in the lateral inboard direction may be spherical, involute or other similar shape. In other words, the tenth surface 56, eleventh surface 60, and twelfth surface 62 of the design in Fig. 1 are replaced by a single surface 66 and that surface 66 may be arc shaped. Thus, the single surface 66 may extend in an arc or in a curvilinear fashion from the first surface 22 to the ninth surface 54 to achieve the same or similar effect to the design described above.

[0053] In a related embodiment, as shown in Fig. 4, a shape 68, such as an hourglass shape 68 or hyperboloid shape 68 or similar shape 68 may be located in the coil housing 14 instead of the armature 20. For example, this shape(s) 68 may be located in the radially inboard innermost surface 18 of the coil housing 14. In such a case, it may be that the armature 20 has a substantially planar surface 70 facing the hour-glass / hyperboloid / similar shape 68 in the coil housing 14. As noted above, Fig. 2 depicts one embodiment of armature tilt. Looking at the upper portion 10a of the system 10 in Fig. 2, it can be seen that the twelfth surface 62 moves into a gap 72 between the surface 62 and the radial inboard innermost surface 18 of the coil housing 14. The extent to which the twelfth surface 62 closes the gap 72 is proportional to the amount of tilt experienced or required. The eleventh surface 60 may rotate about the radial inboard innermost surface 18. The tenth surface 56 simultaneously increases a gap 74 size between the surface 56 and the radial inboard innermost surface 18. It may be appreciated that the increase / decrease in the size / shape of the gaps 72, 74 changes if the armature tilts in the opposite direction.

[0054] Looking at the lower portion 10b of the system 10 it can be seen that the tenth surface 56 moves into gap 74 between the surface 56 and the radial inboard innermost surface 18. The extent to which the tenth surface 56 closes the gap 74 is proportional to the amount of tilt experienced or required. The eleventh surface 60 may rotate about the radial inboard innermost surface 18. The twelfth surface 62 simultaneously increases gap 72 in size between the surface 62 and the radial inboard innermost surface 18. It may be appreciated that the increase / decrease in the size / shape of the gaps 72, 74 changes if the armature tilts in the opposite direction. The gaps 72, 74 may be the same size or they may be different sizes, depending on the geometry of the surfaces used in either the armature 20 or the housing 14.

[0055] In another embodiment that is not depicted in the figures, the planar radially inboard innermost surface of the coil house 14 adjacent to the armature 20 may be replaced with the surfaces described above for the armature 20. In such a case, the adjacent surfaces of the armature 20 may be provided with a substantially planar presentation (e.g., extending generally parallel the x-axis) with respect to the shaped coil housing 14.

[0056] The alternative embodiment noted above can be appreciated from a similar design which is depicted in Fig. 4. In Fig. 4, the radial inboard portion 16 of the solenoid housing 14 may be generally shaped as noted above in the description of Fig. 1 . One exception to Fig. 1 is that the radial inboard innermost surface 18 may now be comprised of a lateral outboard surface 76. The lateral outboard surface 76 may be such as a conical feature formed in the housing 14. The lateral outboard surface may be angled in the radial direction to a cylindrical section 78 of the housing 14. The angle may be the same or similar to an angle at which the armature may tilt during actuation. The cylindrical section 78 may be adapted to be the primary guide, or pilot, for the armature 20 along its generally lateral motion.

[0057] The cylindrical section 78 may transition to a lateral inboard surface 80. The lateral inboard surface 80 may be such as a conical feature formed in the housing 14. The lateral inboard surface 80 may be angled in the radial direction the same or similar extent as the lateral outboard surface 76. It may be in some cases that the lateral length of the lateral inboard surface 80 may not be the same as the lateral length of the lateral outboard surface 76.

[0058] One or more conical shaped gaps 82 may be located between the lateral outboard surface 76 and the armature 20, and between the lateral inboard surface 80 and the armature 20. These gaps 82 may function the same as the gaps 72, 74 in the armature 20 as noted above.

[0059] In some embodiments, as noted above, the angle at which the lateral inboard surface 80 and lateral outboard surface 76 extends into to the housing 14 may be the same or similar to the angle the armature 20 may be tilted. For example, if it is desired to permit the armature 20 to tilt approximately 1 degree, each of the angles may be the same or similar to approximately 1 degree (such as 1 degree measured from below the horizontal).

[0060] The design in Fig. 4 may function in a related manner to the designs noted above to accommodate misalignment of the armature 20 and / or acted upon parts.

[0061] Fig. 4 does not depict a relief in the transfer ring 34, but a relief similar to that depicted in Fig. 1 may be used if so desired.

[0062] In accordance with the provisions of the patent statutes, the present device and process has been described in what is considered to represent its preferred embodiments. However, it should be noted that the device and process can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.

[0063]

Claims

What is claimed is:

1. A non-binding solenoid system, comprising: a coil, wherein said coil is located in a coil housing unit, an armature, wherein said armature comprises a plurality of surfaces, wherein said armature comprises an upper portion and a lower portion, an armature relief portion located in either the inboard portion of the coil housing unit or the upper portion of the armature, wherein said armature relief portion is adapted to allow the armature to rotate with respect to the coil housing unit.

2. The non-binding solenoid system of claim 1 , wherein two of the plurality of surfaces are directly connecting and perpendicular to one another.

3. The non-binding solenoid system of claim 2, wherein the directly connecting and perpendicular surfaces are adapted to receive a transfer ring.

4. The non-binding solenoid system of claim 1 , wherein the armature relief portion comprises a first angled surface, a middle surface, and a second angled surface.

5. The non-binding solenoid system of claim 4, wherein the first angled surface and the second angled surface are angled equally towards one another, and the middle surface is centered between the first angled surface and the second angled surface.

6. The non-binding solenoid system of claim 5, wherein the middle surface is cylindrical and adapted to make slidable contact with the inboard portion of the coil housing unit.

7. The non-binding solenoid system of claim 6, wherein the first angled surface and the second angled surface are adapted to enter gaps between the coil housing unit and the armature.

8. The non-binding solenoid system of claim 1 , wherein the armature relief portion comprises an arced surface that is adapted to make slidable contact with the inboard portion of the coil housing unit.

9. The non-binding solenoid system of claim 1 , wherein the armature relief portion comprises a level surface that is adapted to make slidable contact with the inboard portion of the coil housing unit.

10. The non-binding solenoid system of claim 9, wherein the inboard portion of the coil housing unit comprises a surface that is conically shaped.11 . The non-binding solenoid system of claim 1 , wherein the inboard portion of the coil housing unit at least partially encloses the coil.

12. The non-binding solenoid system of claim 1 , wherein the armature is one piece, integrally formed, and unitary.

13. The non-binding solenoid system of claim 1 , wherein the upper portion of the armature comprises a protruding portion.

14. The non-binding solenoid system of claim 13, wherein the protruding portion is adapted to have a complementary shape to a portion of the coil housing unit with which the protruding portion is in selective direct contact.

5. The non-binding solenoid system of claim 14, wherein the protruding portion is tapered at an angle that is complementary to an angle of the portion of the coil housing unit with which the protruding portion is in selective contact.

Images