Valve actuator

Abstract

A valve actuator includes a non-conductive support bobbin. The non-conductive support bobbin includes a first flange, a second flange, and an interconnecting segment extending between and generally orthogonal to the first flange and the second flange. The valve actuator includes a magnetic flux concentration member including a first arm that extends through the interconnecting segment of the non-conductive support bobbin. The valve actuator includes a nickel-plated wire wound around the interconnecting segment of the non-conductive support bobbin. The valve actuator includes an armature including a valve seal. The valve seal is configured to be aligned with a valve seat of a gas valve. The armature is actuated by magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire.

Description

Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 VALVE ACTUATOR CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63 / 754,696 filed February 6, 2025, the entire contents of which are incorporated herein by reference.FIELD

[0002] This disclosure relates generally to valve actuators. More particularly, this disclosure relates to valve actuators for use in a gas valve assembly.BACKGROUND

[0003] In recent years the quality of fuel gas has become increasingly poor, particularly in warmer regions where drying the gas is not critical and where regulations do not require relatively high levels of gas purity. As a result, gas supplies have had increasing concentrations of hydrogen sulfide, which can be very corrosive. Solenoid coils used in gas valves in natural gas and propane are highly susceptible to corrosion from hydrogen sulfide, which reacts with copper to form copper sulfide, especially in the presence of moisture. Valve actuators or components thereof (e.g., solenoids, copper wires, connection points) which are located within and / or near a gas stream can degrade or break due to the corrosion.SUMMARY

[0004] In some embodiments, a valve actuator includes a non-conductive support bobbin. In some embodiments, the non-conductive support bobbin includes a first flange, a second flange, and an interconnecting segment extending between and generally orthogonal to the first flange and the second flange. In some embodiments, the valve actuator includes a magnetic flux concentration member includes a first arm. In some embodiments, the first arm extends through the interconnecting segment of the non- conductive support bobbin. In some embodiments, the valve actuator includes a nickel- plated wire wound around the interconnecting segment of the non-conductive support bobbin. In some embodiments, the valve actuator includes an armature including a valve seal. In some embodiments, the valve seal is configured to be aligned with a valve seat of a gas valve. In some embodiments, the armature is actuated by magnetic attraction to the1ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 magnetic flux concentration member when a current is applied through the nickel-plated wire.

[0005] In some embodiments, the nickel-plated wire is uncoated.

[0006] In some embodiments, the valve actuator further includes a strain relief member disposed on the second flange. In some embodiments, a first portion of the nickel-plated wire is wound around the strain relief member.

[0007] In some embodiments, a first end of the nickel-plated wire extends from the strain relief member and is configured to be electrically coupled to an interconnect pin.

[0008] In some embodiments, the valve actuator further includes a ground terminal electrically coupled to a second end of the nickel-plated wire.

[0009] In some embodiments, the second end of the nickel-plated wire is soldered to the ground terminal to form a soldered connection.

[0010] In some embodiments, the soldered connection is coated with a first coating.

[0011] In some embodiments, the first flange includes a first slot formed in the non- conductive support bobbin. In some embodiments, the ground terminal is disposed at least in part within the first slot.

[0012] In some embodiments, the ground terminal is supported by the first flange and is bent toward the second flange. In some embodiments, the ground terminal overlaps at least part of the nickel-plated wire.

[0013] In some embodiments, the ground terminal is electrically connected to a ground spring.

[0014] In some embodiments, a gas valve assembly includes a housing and a valve actuator disposed within the housing. In some embodiments, the valve actuator includes a non-conductive support bobbin. In some embodiments, the non-conductive support bobbin includes a first flange, a second flange, and an interconnecting segment extending between and generally orthogonal to the first flange and the second flange. In some embodiments, the valve actuator includes a magnetic flux concentration member includes a first arm. In some embodiments, the first arm extends through the interconnecting segment of the non- conductive support bobbin. In some embodiments, the valve actuator includes a nickel- plated wire wound around the interconnecting segment of the non-conductive support 2ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 bobbin. In some embodiments, the valve actuator includes an armature including a valve seal. In some embodiments, the valve seal is configured to be aligned with a valve seat of a gas valve. In some embodiments, the armature is actuated by magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire.

[0015] In some embodiments, the nickel-plated wire is uncoated.

[0016] In some embodiments, the valve actuator further includes a strain relief member disposed on the second flange. In some embodiments, a first portion of the nickel-plated wire is wound around the strain relief member.

[0017] In some embodiments, a first end of the nickel-plated wire extends from the strain relief member and is configured to be electrically coupled to an interconnect pin.

[0018] In some embodiments, the valve actuator further includes a ground terminal electrically coupled to a second end of the nickel-plated wire.

[0019] In some embodiments, the second end of the nickel-plated wire is soldered to the ground terminal to form a soldered connection.

[0020] In some embodiments, the soldered connection is coated with a first coating.

[0021] In some embodiments, the first flange includes a first slot formed in the non- conductive support bobbin. In some embodiments, the ground terminal is disposed at least in part within the first slot.

[0022] In some embodiments, the ground terminal is supported by the first flange and is bent toward the second flange. In some embodiments, the ground terminal overlaps at least part of the nickel-plated wire.

[0023] In some embodiments, the ground terminal is electrically connected to a ground spring.

[0024] In some embodiments, the housing includes a plurality of valve actuators.

[0025] In some embodiments, a gas-powered appliance includes a burner and a gas valve assembly. In some embodiments, the gas valve assembly includes a housing and a valve actuator disposed within the housing. In some embodiments, the valve actuator includes a non-conductive support bobbin. In some embodiments, the non-conductive3ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 support bobbin includes a first flange, a second flange, and an interconnecting segment extending between and generally orthogonal to the first flange and the second flange. In some embodiments, the valve actuator includes a magnetic flux concentration member includes a first arm. In some embodiments, the first arm extends through the interconnecting segment of the non-conductive support bobbin. In some embodiments, the valve actuator includes a nickel-plated wire wound around the interconnecting segment of the non-conductive support bobbin. In some embodiments, the valve actuator includes an armature including a valve seal. In some embodiments, the valve seal is configured to be aligned with a valve seat of a gas valve. In some embodiments, the armature is actuated by magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire.

[0026] In some embodiments, the nickel-plated wire is uncoated.

[0027] In some embodiments, the valve actuator further includes a strain relief member disposed on the second flange. In some embodiments, a first portion of the nickel-plated wire is wound around the strain relief member.

[0028] In some embodiments, a first end of the nickel-plated wire extends from the strain relief member and is configured to be electrically coupled to an interconnect pin.

[0029] In some embodiments, the valve actuator further includes a ground terminal electrically coupled to a second end of the nickel-plated ware.

[0030] In some embodiments, the second end of the nickel-plated wire is soldered to the ground terminal to form a soldered connection.

[0031] In some embodiments, the soldered connection is coated with a first coating.

[0032] In some embodiments, the first flange includes a first slot formed in the non- conductive support bobbin. In some embodiments, the ground terminal is disposed at least in part within the first slot.

[0033] In some embodiments, the ground terminal is supported by the first flange and is bent toward the second flange. In some embodiments, the ground terminal overlaps at least part of the nickel-plated wire.

[0034] In some embodiments, the ground terminal is electrically connected to a ground spring.4ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026

[0035] In some embodiments, the housing includes a plurality of valve actuators.

[0036] In some embodiments, a gas-powered appliance includes a burner; and a gas valve assembly. In some embodiments, the gas valve assembly includes a housing and a valve actuator disposed within the housing. In some embodiments, the valve actuator includes a non-conductive support bobbin; a magnetic flux concentration member; a nickel - plated wire wound around the non-conductive support bobbin; and a valve seal. In some embodiments, the valve seal is configured to be aligned with a valve seat of a gas valve. In some embodiments, magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire controls a state of the gas valve.BRIEF DESCRIPTION OF THE DRAWINGS

[0037] References are made to the accompanying drawings that form a part of this disclosure and that illustrate embodiments in which the systems and methods described in this Specification can be practiced.

[0038] FIG. 1 provides a schematic view of a water heater, according to some embodiments.

[0039] FIG. 2 is a perspective view of a gas valve, according to some embodiments.

[0040] FIG. 3 illustrates a perspective view of an electronic valve actuator, according to some embodiments.

[0041] FIG. 4 shows a perspective view of the support bobbin of FIG. 3, according to some embodiments.

[0042] FIG. 5 shows a perspective view of the ground terminal of FIG. 3, according to some embodiments.

[0043] FIG. 6 shows a side view of an electronic valve actuator, according to some embodiments.

[0044] Like reference numbers represent the same or similar parts throughout.DETAILED DESCRIPTION

[0045] Flame powered gas valves often require solenoid components (such as magnetic wire) to be contained in the gas stream. The enamel coating on magnetic wire is porous. This can be problematic because the wire is made from copper, which corrodes when5ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 exposed to hydrogen sulfide and moisture, both of which are generally present at some level in the gas stream. Corrosion through the wire can lead to increased resistance and eventually an open circuit. An open circuit results in a non-functional device in the field. The failure is usually instantaneous with the opening of the circuit. Past valve actuators have relied upon application of coatings to the magnet wire to protect the magnet wire from corrosion. Generally, the coatings require specialized equipment and substantial processing time to coat the wiring in the valve actuator.

[0046] Embodiments of this disclosure are directed to valve actuators that do not require a special coating (e.g., uncoated) to protect the wire from the corrosive environment. Embodiments of this disclosure include nickel-plated wiring. The nickel plating on the wire provides a barrier to the hydrogen sulfide and can provide a more reliable valve actuator without requiring the cumbersome coatings from prior devices.

[0047] FIG. 1 provides a schematic view of a water heater 100, according to some embodiments. For simplicity of this disclosure, a water heater is used as an example. It is to be appreciated that while a water heater is described as an example application, there are many other applications for the gas valves described in this disclosure. For example, the gas valves disclosed in this disclosure can be used in other combustion appliances such as, but not limited to, furnaces, boilers, gas dryers, other combustion appliances, or the like. Additionally, the gas valves discussed can be used in industrial applications, such as, but not limited to, in distillation towers, other process applications, or the like.

[0048] In the illustrated embodiment, the water heater 100 includes a water heater tank 102. The water heater tank 102 can include an insulating layer (not shown) positioned about the water heater tank 102 to help reduce thermal losses from the water heater tank 102. In operation, cold water enters water heater tank 102 through a cold water line 104 and is heated by a gas burner 114. The resulting heated water exits through a hot water line 106. For gas-fired water heaters, a gas control unit 108, such as a gas valve, regulates gas flow from a gas source 110 through a combustion gas line 112 and into gas burner 114. A flue 116 permits combustion byproducts to safely exit.

[0049] In some embodiments, water heater 100 can include a temperature sensor 118. In some embodiments, the temperature sensor 118 can enter water heater tank 102 at a location laterally offset, vertically offset, or a combination thereof, from gas control unit6ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 108. In some embodiments, the temperature sensor 118 can instead be located behind gas control unit 108. In some embodiments, the temperature sensor 118 can be supported and retained by a common mounting bracket. In some embodiments, a non-immersion type temperature sensor can be used.

[0050] FIG. 2 is a perspective view of a gas valve 150, according to some embodiments. The gas valve 150 includes a valve body 152 that has a gas inlet 154, a gas outlet 156, and a conduit connecting the gas inlet 154 to the gas outlet 156. In some embodiments, the valve body 152 can be a single piece molded or cast structure. In some embodiments, a cover of the valve body 152 can be removeable. In some embodiments, the valve body 152 can include a pilot burner outlet 158 configured to provide combustion gas to a pilot burner.

[0051] FIG. 3 illustrates a perspective view of an electronic valve actuator 200, according to some embodiments. In some embodiments, the electronic valve actuator 200 can be installed within the valve body 152 (FIG. 2) to control an output of combustion gas from the gas outlet 156 (FIG. 2) or the pilot burner outlet 158 (FIG. 2).

[0052] In some embodiments, the electronic valve actuator 200 includes a non- conductive support member or bobbin (a support bobbin 202). A conductive wire 204 can be wound around at least a portion of the support bobbin 202 to form a magnetic coil. In some embodiments, the conductive wire 204 includes a wire that is not susceptible to hydrogen sulfide corrosion. In some embodiments, the conductive wire 204 is a nickel- plated wire. In some embodiments, the conductive wire 204 does not include an additional corrosion-resistant coating.

[0053] In some embodiments, the conductive wire 204 can have a length wound about the support bobbin 202. The length can be selected to generate a predetermined magnetic field when current flows through the conductive wire 204. In some embodiments, a first end portion 212 of the conductive wire 204 can be electrically coupled to aground terminal 206. In some embodiments, a second end portion 214 of the conductive wire 204 can be electrically coupled with an interconnect pin 210. The interconnect pin 210 can be configured to be electrically connected to a power source, controller, or other mechanism for selectively supplying current to the conductive wire to control the open or close position of the electronic valve actuator 200. In some embodiments, a portion of the conductive wire7ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 204 can also be coupled to a strain relief member 211 between the support bobbin 202 and the interconnect pin 210 to reduce likelihood of breakage of the conductive wire 204.

[0054] In some embodiments, the coupling of the second end portion 214 to the interconnect pin 210 can be beneficial relative to prior valve actuators which can include an additional interconnect terminal and then leverage a more expensive wire between the additional interconnect terminal and the interconnect pin 210. In some embodiments, reducing a connection point for the wiring to just the two ends can also improve an overall reliability of the electronic valve actuator 200. In some embodiments, the connection is created by a soldered connection. In some embodiments, the soldered connection can be coated for protection. In some embodiments, the coating can be, but is not limited to, polyurethane or the like.

[0055] In some embodiments, the electronic valve actuator 200 can include a magnetic flux concentration member 216. The magnetic flux concentration member 216 can be, for example, a soft ferromagnetic (or ferrimagnetic) material, such as iron or the like. As will be described in more detail below, at least a portion of the magnetic flux concentration member 216 can extend through a portion of the support bobbin 202.

[0056] In some embodiments, an armature 218 can be positioned along a lateral side of the support bobbin 202. The armature 218 can be movable between a first position and a second position to maintain a valve seal 220 in a closed configuration or an open configuration, as desired, to enable or disable flow of combustion gas in the gas valve 150 (FIG. 2). A spring 222, or other biasing mechanism, can extend between the armature 218 and a first laterally extending portion 224 of the support bobbin 202. In the example shown, the spring 222 can exert a bias force on the armature 218 to bias the valve seal 220 into a normally closed configuration. When the armature 218 is in the closed configuration, the valve seal 220 can contact a valve seat of the valve body 152 (FIG. 2) and prevent a flow of gas therethrough.

[0057] In some embodiments, as an electrical current is passed through the conductive wire 204 (provided via the interconnect pin 210), a magnetic field is generated and collected by the magnetic flux concentration member 216. A magnetic attraction between the armature 218 and the magnetic flux concentration member 216 can be used to move the armature 218 from the normally closed configuration to an open configuration. In the8ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 example shown, a first end 219 of armature 218 can be attracted to and contact the magnetic flux concentration member 216 and 209. This magnetic attraction can cause the armature 218 to overcome the biasing force of the spring 222 and move such that the valve seal 220 is lifted upward in FIG. 3 and away from a valve seat (not shown), allowing a flow of gas to pass by the valve seat of the valve body 152 (FIG. 2). In some embodiments, when the armature 218 is in a closed configuration, the first end 219 of armature 218 can contact an underside of the first laterally extending portion 224 and when the armature is in an open configuration the first end 219 of armature 218 can be spaced a distance from the underside of the first laterally extending portion 224.

[0058] FIG. 4 shows a perspective view of the support bobbin 202 of FIG. 3, according to some embodiments. FIG. 5 show s a perspective view of the ground terminal 206 of FIG.3, according to some embodiments. For simplicity of this Specification, FIG. 4 and FIG. 5 will be referenced collectively, unless specifically noted otherwise.

[0059] In some embodiments, the support bobbin 202 can include a first flange 226. a second flange 228 spaced from the first flange 226, and an interconnecting segment 230 extending between and generally orthogonal to the first flange 226 and the second flange 228. In some embodiments, the first flange 226 and the second flange 228 can have a thickness and be formed from a material sufficient to prevent flexing during winding of the conductive wire 204 on the interconnecting segment 230. In some embodiments, this can help prevent flexing of the first flange 226 and the second flange 228 during winding which can result in an interference betw een the support bobbin 202 and the valve body 152 (FIG.2). For example, if the support bobbin 202 flexes or otherwise deforms during assembly, alignment issues with, for example, the valve seal 220, can be created.

[0060] In some embodiments, the first flange 226 can include a first slot 232 extending from a top surface 234 of the first flange 226 towards a bottom surface thereof. In some embodiments, the first slot 232 can be configured to receive at least a portion of the ground terminal 206 (see FIG. 5 below). In some embodiments, the first slot 232 can include alignment features, such as but not limited to, a bend or curve 242 configured to maintain proper alignment of the ground terminal 206 within the first slot 232. In some embodiments, the ground terminal 206 can include a bend or curve 264 configured to align with the curve in the first slot 232. It is to be appreciated that other alignment features can be used, as desired, to align the ground terminal 206 within the first slot 232.9ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026

[0061] The first slot 232 can further include an enlarged region or pocket 240 configured to receive a connection element, such as. but not limited to, a ground spring 244 (FIG. 3) configured to provide an electrical connection between the ground terminal 206 and the valve body 152 (FIG. 2). In some instances, the ground terminal 206 can have a pad 266 positioned at a bottom of the pocket 240 to make the electrical connection from the ground terminal 206 to the ground spring 244. In some embodiments, the support bobbin 202 can be positioned between the ground terminal 206 and the magnetic flux concentration member 216 such that the ground terminal 206 is unable to short to the magnetic flux concentration member 216 (and thus create a second ground path that can be unreliable and create a false pass scenario in production testing of the ground connection).

[0062] In some embodiments, the pocket 240 can include a biasing element configured to bias the ground spring 244 towards an alignment feature 260 such as, but not limited to, a V-block feature molded within the pocket 240. In some embodiments, the alignment feature 260 can help ensure precise positioning of the ground spring 244, which can be beneficial to locating the ground spring 244 at a particular location within the valve body 152 (FIG. 2). In some embodiments, the biasing element can have a specific profile that allows it to be flexible enough to accommodate a range of sizes for the ground spring 244 and pocket 240 size tolerances that occur during manufacture, while not putting so much radial force on the ground spring 244 that it interferes with proper compression of the ground spring 244. In some embodiments, the biasing element can help prevent the ground spring 244 from being loose within the pocket 240 which can reduce shifting of the ground spring 244 during assembly of the valve body 152 (FIG. 2) and can also prevent the ground spring 244 from falling out of the pocket 240 during assembly.

[0063] The second flange 228 can include the strain relief member 211. In some embodiments, a portion of the conductive wire 204 can be wrapped around the strain relief member 211 to reduce strain on the second end portion 214 connected to the interconnect pin 210.

[0064] In some embodiments, the first flange 226 can further include an additional slot 238 extending along and through a portion of a lateral side surface 236 of the first flange 226. In some embodiments, the additional slot 238 can allow the conductive wire 204 to be led into the center of the support bobbin 202 which can help prevent direct contact between10ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 the start of the winding and the end of the winding portions (e.g., the first end portion 212 and the second end portion 214 of the conductive wire 204).

[0065] The first flange 226 can include an aperture 250 configured to receive a locking tab 268 on the ground terminal 206. The locking tab 268 and corresponding aperture 250 can cooperate to form a snap locking feature to retain the ground terminal 206 within the first slot 232 by way of a mechanical engagement of the locking tab 268 and the aperture 250. For example, the locking tab 268 on the ground terminal 206 can be deflectable such that the locking tab 268 is biased for assembly of the ground terminal 206 into the first slot 232 and return to its original configuration once aligned with the aperture 250.

[0066] The first flange 226 can further include an alignment feature 252 that extends laterally. The alignment feature 252 can extend away from the interconnecting segment 230 and can be configured to align and mate with a corresponding feature in the valve body 152. The alignment feature 252 can help retain the electronic valve actuator 200 in a desired position within the valve body 152. The second flange 228 can include a first laterally extending portion 224 and a second laterally extending portion 254, each extending in a direction away from the interconnecting segment 230. The second laterally extending portion 254 can be configured to receive a portion of the armature 218 and to provide a pivot point for the armature 218. In some instances, the second laterally extending portion 254 can be configured to mate with corresponding features on the armature to align the armature 218 as well as to minimize axial movement of the armature 218. In addition to providing a mechanical stop for the spring 222, the first laterally extending portion 224 can also create a mechanical stop for a second end of the armature 218.

[0067] The support bobbin 202 can include a passageway 256 extending from the first flange 226 through the interconnecting segment 230 and to the second flange 228 (see FIG.4). The passageway 256 can extend through an entirety of the width of the first flange 226 and an entirety of the width of the second flange 228. The passageway 256 can be configured to receive at least a portion of the magnetic flux concentration member 216.

[0068] In some embodiments, the ground terminal 206 can be a tin-nickel (tin over nickel flash) plated brass electrical terminal. However, it is contemplated that the ground terminal 206 can be formed from different materials, as desired. In some examples, the ground terminal 206 can be formed from aluminum or nickel. In yet another example, the11ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 ground terminal 206 can be a brass electrical terminal with either nickel electroplating or electroless nickel plating. It is contemplated that the ground terminal 206 can be formed by stamping and subsequently bending to form the ground terminal 206 into its final shape. In some instances, the ground terminal 206 can be plated prior to stamping. After the support bobbin 202 is wound and the conductive wire 204 is soldered to (or otherwise coupled) to the ground terminal 206 or the interconnect pin 210. all or a portion of the ground terminal 206 and solder and the interconnect pin 210 and solder can be protected from corrosion by covering it (or portions thereol with an ultraviolet (UV) cured adhesive, Chemglaze® polyurethane (manufactured by the Lord Corporation, Erie, Pa.), fluoro-acrylate, or a similar coating that is not permeable to hydrogen sulfide.

[0069] The ground terminal 206 can include a bendable or deformable arm 262 that is configured to be electrically coupled to the first end portion 212 of the conductive wire 204. It is contemplated that the arm 262 can be positioned generally orthogonal to the longitudinal axis of the support bobbin 202 (e.g., generally orthogonal to the interconnecting segment 230 or generally parallel to the first flange 226) when the ground terminal 206 is snap fit within the first slot 232 of the first flange 226. In other words, to assemble the ground terminal 206 within the support bobbin 202, the arm 262 can be positioned generally parallel to the first flange 226. The ground terminal 206 can be positioned within the first slot 232 until the locking tab 268 engages the aperture 250. In some instances, the arm 262 can be bent beyond perpendicular in a direction away from the interconnecting segment 230 to ensure the conductive wire 204 does not catch on the ground terminal 206 during winding of the conductive wire 204 on the interconnecting segment 230. It is contemplated that the arm 262 can remain in this configuration while the conductive wire 204 is connected to the arm 262.

[0070] The second end portion 214 of the conductive wire 204 can be wound about and / or soldered to (or otherwise electrically coupled with) an end region 263 of the arm 262. In some instances, the end region 263 can include one or more features 267 configured to direct or position the conductive wire 204 around the arm 262. These one or more features 267 can help ensure the first end portion 212 of the conductive wire 204 is located optimally for termination (e.g., placement of the first end portion 212 of the conductive wire 204) and folding down of the arm 262 over the resulting coil after the conductive wire 204 has been wound. The conductive wire 204 can be directed along an underside surface12ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 265 of the arm 262 and down through the additional slot 238 in the first flange 226 and towards the interconnecting segment 230. As described above, directing the conductive wire 204 through the slot 238 can lead the conductive wire 204 to the center (e.g., the interconnecting segment 230) of the support bobbin 202, which can prevent direct contact between the first end portion 212 and the second end portion 214 of the conductive wire 204. The conductive wire 204 can then be wound about the interconnecting segment 230 until a desired length of conductive wire 204 is disposed about the interconnecting segment 230 to produce a desired magnetic field during operation. The second end portion 214 of the conductive wire 204 can be coupled to the strain relief member 211. Once the winding is complete, the arm 262 can be bent inward over the winding such that it extends generally parallel to the longitudinal axis of the support bobbin 202 and towards the second flange 228. In some cases, bending of the arm 262 is not be required or the arm 262 can be bent in a direction other than inw ard.

[0071] FIG. 6 shows a side view of an electronic valve actuator 300, according to some embodiments. In some embodiments, the electronic valve actuator 300 can be a different geometry than the electronic valve actuator 200 (FIG. 3). Like the electronic valve actuator 200 (FIG. 3), the electronic valve actuator 300 can be installed within a valve body to control an output of combustion gas from a gas outlet or pilot burner outlet.

[0072] In some embodiments, the electronic valve actuator 300 includes a non- conductive support member or bobbin (a support bobbin 302). In some embodiments, the support bobbin 302 can be cylindrical in shape. In some embodiments, a conductive wire 304 can be wound around at least a portion of the support bobbin 302 to form a magnetic coil. In some embodiments, the conductive wire 304 is not susceptible to hydrogen sulfide corrosion. In some embodiments, the conductive wire 304 is a nickel-plated wire. In some embodiments, the conductive wire 304 does not include an additional corrosion-resistant coating.

[0073] In some embodiments, the conductive wire 304 can have a length wound about the support bobbin 302. In some embodiments, the length can be selected to generate a predetermined magnetic field when current flows through the conductive wire 304. The support bobbin 302 can be held within a frame 306. An end portion of the conductive wire 304 can be electrically coupled with a power terminal 308. The power terminal 308 can be configured to be electrically connected to a pow er source, controller, or other mechanism 13ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 for selectively supplying current to the conductive wire to control the open or close position of the electronic valve actuator 300.

[0074] In some embodiments, the electronic valve actuator 300 includes a member 310 disposed within an opening of the support bobbin 302. As a result, when current is supplied to the power terminal 308 and accordingly the conductive wire 304, the member 310 can be moved relative to a stop 312 (e.g., in the left-right horizontal direction with respect to the page of the illustration), thereby causing an opening or closing of the electronic valve actuator 300.

[0075] It is to be appreciated that the electronic valve actuator 200 (FIG. 3) and the 300 (FIG. 6) are two examples of geometries for valve actuators that are used in corrosive environments. Other geometries are contemplated and can include the nickel-plated wire to reduce impacts from hydrogen sulfide and moisture driven corrosion.

[0076] The terminology used herein is intended to describe embodiments and is not intended to be limiting. The terms “a,” “an,” and “the” include the plural forms as well, unless clearly indicated otherwise. The terms “comprises” and / or “comprising,” when used in this Specification, specify the presence of the 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, and / or components.

[0077] It is to be understood that changes can be made in detail, especially in matters of the construction materials employed and the shape, size, and arrangement of parts without departing from the scope of the present disclosure. This Specification and the embodiments described are examples, with the true scope and spirit of the disclosure being indicated by the claims that follow.14ACTIVE 718856087v1

Claims

Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 CLAIMS1. A valve actuator comprising:a non-conductive support bobbin,wherein the non-conductive support bobbin includes:a first flange,a second flange, andan interconnecting segment extending between and generally orthogonal to the first flange and the second flange;a magnetic flux concentration member comprising:a first arm,wherein the first arm extends through the interconnecting segment of the non-conductive support bobbin;a nickel-plated wire wound around the interconnecting segment of the non-conductive support bobbin; andan armature comprising a valve seal,wherein the valve seal is configured to be aligned with a valve seat of a gas valve,wherein the armature is actuated by magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire.

2. The valve actuator of claim 1, wherein the nickel-plated wire is uncoated.

3. The valve actuator of claim 1, further comprising a strain relief member disposed on the second flange;wherein a first portion of the nickel-plated wire is wound around the strain relief member.

4. The valve actuator of claim 3, wherein a first end of the nickel-plated wire extends from the strain relief member and is configured to be electrically coupled to an interconnect pin.15ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 5. The valve actuator of claim 1. further comprising a ground terminal electrically coupled to a second end of the nickel-plated wire.

6. The valve actuator of claim 5, wherein the second end of the nickel-plated wire is soldered to the ground terminal to form a soldered connection.

7. The valve actuator of claim 6, wherein the soldered connection is coated with a first coating.

8. The valve actuator of claim 5. wherein the first flange comprises a first slot formed in the non-conductive support bobbin;wherein the ground terminal is disposed at least in part within the first slot.

9. The valve actuator of claim 8, wherein the ground terminal is supported by the first flange and is bent toward the second flange;wherein the ground terminal overlaps at least part of the nickel-plated wire.

10. The valve actuator of claim 9, wherein the ground terminal is electrically connected to a ground spring.

11. A gas valve assembly comprising:a housing; anda valve actuator disposed within the housing, the valve actuator comprising:a non-conductive support bobbin,wherein the non-conductive support bobbin includes:a first flange,a second flange, andan interconnecting segment extending between and generally orthogonal to the first flange and the second flange;a magnetic flux concentration member comprising:a first arm,wherein the first arm extends through the interconnecting segment of the non-conductive support bobbin;16ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 a nickel-plated wire wound around the interconnecting segment of the non- conductive support bobbin; andan armature comprising a valve seal,wherein the valve seal is configured to be aligned with a valve seat of a gas valve,wherein the armature is actuated by magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire.

12. The gas valve assembly of claim 11, wherein the nickel-plated wire is uncoated.

13. The gas valve assembly of claim 11, further comprising a strain relief member disposed on the second flange;wherein a first portion of the nickel-plated wire is wound around the strain relief member.

14. The gas valve assembly of claim 13, wherein a first end of the nickel-plated wire extends from the strain relief member and is configured to be electrically coupled to an interconnect pin.

15. The gas valve assembly of claim 11, further comprising a ground terminal electrically coupled to a second end of the nickel-plated wire.

16. The gas valve assembly of claim 15, wherein the second end of the nickel-plated wire is soldered to the ground terminal to form a soldered connection.

17. The gas valve assembly of claim 16, wherein the soldered connection is coated with a first coating.

18. The gas valve assembly of claim 15, wherein the first flange comprises a first slot formed in the non-conductive support bobbin;wherein the ground terminal is disposed at least in part within the first slot.17ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 2026 19. The gas valve assembly of claim 18, wherein the ground terminal is supported by the first flange and is bent toward the second flange;wherein the ground terminal overlaps at least part of the nickel-plated wire.

20. The gas valve assembly of claim 19, wherein the ground terminal is electrically connected to a ground spring.

21. The gas valve assembly of claim 11, wherein the housing comprises a plurality of valve actuators.

22. A gas-powered appliance comprising:a burner; anda gas valve assembly comprising:a housing; anda valve actuator disposed within the housing, the valve actuator comprising:a non-conductive support bobbin,wherein the non-conductive support bobbin includes:a first flange,a second flange, andan interconnecting segment extending between and generally orthogonal to the first flange and the second flange; a magnetic flux concentration member comprising:a first arm,wherein the first arm extends through the interconnecting segment of the non-conductive support bobbin;a nickel-plated wire wound around the interconnecting segment of the non-conductive support bobbin; andan armature comprising a valve seal,wherein the valve seal is configured to be aligned with a valve seat of a gas valve,wherein the armature is actuated by magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire.18ACTIVE 718856087v1Attorney Docket No. 203863-018001 / PCT Resideo Ref. No. R214359-WO Electronically Filed: February 6, 202623. A gas-powered appliance comprising:a burner; anda gas valve assembly comprising:a housing; anda valve actuator disposed within the housing, the valve actuator comprising:a non-conductive support bobbin;a magnetic flux concentration member;a nickel-plated wire wound around the non-conductive support bobbin; anda valve seal,wherein the valve seal is configured to be aligned with a valve seat of a gas valve,wherein magnetic attraction to the magnetic flux concentration member when a current is applied through the nickel-plated wire controls a state of the gas valve.19ACTIVE 718856087v1

Images