Sacrificial reactive element coil assembly

Abstract

A sacrificial reactive layer that mitigates ammonia attack on coil windings from ammonia is used in a sacrificial reactive element coil assembly in a solenoid. The sacrificial reactive element coil assembly includes a bobbin, a coil wound on the bobbin, the sacrificial reactive layer that is assembled with the coil, a barrier provided around the sacrificial reactive layer to accommodate the bobbin, the coil, and the sacrificial reactive layer. The sacrificial reactive layer has a high affinity to react with ammonia and needs only to be placed near the coil such that the ammonia will react with the sacrificial reactive layer to consume the ammonia. As a result, a local ammonia-depleted environment is created in the region around the sacrificial reactive layer and the coil, thereby mitigating ammonia attack on the coil.

Description

WWD Ref: XS-3724Aty Docket No 11320-00930SACRIFICIAL REACTIVE ELEMENT COIL ASSEMBLYCross-Reference to Related Application:

[0001] The present application claims the benefit of U.S. Provisional Application No. 63 / 775,576 filed on March 21, 2025, which is incorporated herein by reference.TECHNICAL FIELD

[0002] This application generally relates to solenoids, and more particularly to a sacrificial reactive element positioned near one or more electrical coils of the solenoid for use in solenoid operated gas admission valves or other electromechanical device.BACKGROUND

[0003] Solenoid Operated Gas Admission Valves (SOGAVs) are a family of electrically-actuated, high-response gas admission valves for in-manifold (port) fuel admission. SOGAVs are typically used on four cycle, turbocharged, natural gas or dual-fuel engines where one SOGAV valve is required for each cylinder. The SOGAV valve is designed as the valve portion of an overall gaseous fuel admission system delivering precise gas mass flow metering per cylinder. This enables gas engines and dual-fuel engines to operate lean burn, with increased efficiency and reduced emissions.

[0004] Internal combustion engines, including diesel engines and dual-fuel diesel-ammonia engines, ignite an air-fuel mixture to produce combustion in one or more engine cylinders. Ammonia based fuel is used in many industries including industrial applications, marine applications such as cruise ships or other large marine vessels, power plants, and agriculture, to name a few. Common wires and insulation materials used in solenoids and other electromechanical devices are not compatible with ammonia. These materials are attacked, degraded, and / or corroded by ammonia environments.

[0005] Therefore, further contributions in this area of technology are needed to improve the durability of SOGAVs and electromechanical devices in general for use in ammonia-based applications.WWD Ref: XS-3724Aty Docket No 11320-00930SUMMARY

[0006] An exemplary embodiment includes a sacrificial reactive element coil assembly for use in an electromagnetic actuator in an ammonia environment. The sacrificial reactive element coil assembly includes a bobbin, a coil wound on the bobbin, a sacrificial reactive layer configured to mitigate ammonia attack on the coil, wherein the sacrificial reactive layer is assembled with the coil, and a barrier provided around the sacrificial reactive layer to accommodate the bobbin, the coil, and the sacrificial reactive layer. The barrier can include a potting and / or a sleeve assembled with the sacrificial reactive layer.

[0007] The sacrificial reactive layer has a high affinity to react with ammonia and is placed near the coil such that the ammonia will react with the sacrificial reactive layer to thereby consume the ammonia. As a result, a local ammonia-depleted environment is created in the region around the sacrificial reactive layer and the coil, thereby mitigating ammonia attack on the coil. The coil includes a wire that is typically made of material that would be subject to ammonia attack. The coil includes insulation to cover the wire. The insulation is typically made of polymer or other material that would be subject to ammonia attack and then become brittle and / or crack which leads to degradation of the electromagnetic actuator performance. The sacrificial reactive layer assembled with the sacrificial reactive element coil assembly allows the wires made of copper material and the insulation made of polymer material that are optimal from the standpoint of magnetic performance, commercially availability, manufacturability, and cost, and that would not otherwise survive in ammonia, to be used in ammonia environments.

[0008] This summary is provided to introduce a selection of concepts that are further described below in the illustrative embodiments. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.WWD Ref: XS-3724Aty Docket No 11320-00930BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The concepts described herein are illustrative by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. Where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements.

[0010] FIG. l is a front perspective view of an embodiment of a sacrificial reactive element coil assembly of the present disclosure;

[0011] FIG. 2 is a rear perspective view of the sacrificial reactive element coil assembly of FIG. 1;

[0012] FIG. 3 is a schematic cross-sectional view of the sacrificial reactive element coil assembly of FIG. 1 assembled on a schematic representation of a SOGAV solenoid; and

[0013] FIG. 4 is a perspective view of an embodiment of a laminated stator for assembly with the sacrificial reactive element coil assembly of FIG. 3.WWD Ref: XS-3724Aty Docket No 11320-00930DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0014] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated embodiments, and any further applications of the principles of the invention as illustrated therein as would normally occur to one skilled in the art to which the invention relates are contemplated herein.

[0015] With reference to FIGS. 1-3, there is illustrated an embodiment of a sacrificial reactive element coil assembly 100 constructed in accordance with an embodiment of the present application. The sacrificial reactive element coil assembly 100 is assembled with a SOGAV solenoid 500. The sacrificial reactive element coil assembly 100 includes a bobbin 104, a barrier that can include either a potting 106 and / or a sleeve 102, a sacrificial reactive layer 108, and a solenoid coil 124. In FIG. 3, the sacrificial reactive element coil assembly 100 includes the sleeve 102, however in other embodiments the sleeve 102 may not be assembled with the sacrificial reactive element coil assembly 100. FIGS. 1 and 2 do not include the sleeve 102 to better illustrate the sacrificial reactive layer 108. The sacrificial reactive element coil assembly 100 is assembled with a stator 126 wherein an exemplary embodiment of the stator 126 is illustrated in FIG. 4.

[0016] The sleeve 102 forms an outermost side 103 and bottom protective wall 105 of the sacrificial reactive element coil assembly 100. The sleeve 102 may be made of any suitable plastic material.

[0017] The bobbin 104 may be formed as an elongated oval or other geometric shape to accommodate the coil for a particular application. The material selected for the bobbin 104 may be any approved non-magnetic composition selected based on operating environment and application. The bobbin 104 includes an inner side wall 107 that includes a pair of sides 110 that extend between a pair of end portions 111 with a rounded comer 120 at each of the transitions between the sides 110 and the end portions 111. The bobbin 104 includes a bottom wall 109 and a top wall 113 that extends from the inner side wall 107.

[0018] Depending on the application in which the sacrificial reactive element coil assembly 100 is used, the bobbin 104 may also include retention latches 122 that allow theWWD Ref: XS-3724Aty Docket No 11320-00930sacrificial reactive element coil assembly 100 to be affixed to the stator 126 (FIG. 4) on which the sacrificial reactive element coil assembly 100 is mounted. The retention latches 122 are optional and may not be included with the bobbin 104 in other embodiments.

[0019] As illustrated in FIGS. 1-2, the sacrificial reactive element coil assembly 100 includes a coil wire 112 surrounded by an insulation layer 114. The coil wire 112 and insulation layer 114 enter the bobbin 104 at a coil wire inlet port 116. While not shown in FIGS. 1-2, the coil wire 112 is then wound within the bobbin 104 to form the solenoid coil 124. The coil wire 112 exits the bobbin 104 on the end of the sacrificial reactive element coil assembly 100 via the coil wire outlet port 118.

[0020] Turning to FIG. 3, a schematic cross-section of the sacrificial reactive element coil assembly 100 of FIG. 1 taken through the middle along its longitudinal axis is provided to illustrate the internal features not visible in the perspective views of FIG. 1 or FIG. 2. The sleeve 102 including the outermost side 103 and the bottom protective wall 105 cooperate with the bottom wall 109 of the bobbin 104 to fully enclose the coil 124 wound thereon.

[0021] The potting 106 can be provided in an area between the sidewall of sleeve 102 and the coil 124, i.e., the areas within the sacrificial reactive element coil assembly 100 that are not fully occupied by the bobbin 104, the wire 112 and its insulation 114, or the coil 124 itself. If a crack were to occur in this area of the potting 106, the sleeve 102 would prevent propagation there to the environment. The material for the potting 106 may be selected based on operating conditions and applications. In other embodiments, the size and location of the potting 106 relative to the coil 124 can vary depending on the isolation requirements of the operating environment. The material for the potting 106 can include a standard two-part epoxy utilized in electrical assemblies, e.g., to provide the potting of solenoid coils. In one embodiment, the material for the potting 106 may also include a sacrificial reactive material that is interspersed or mixed with other material for the potting 106. The sacrificial reactive material mixed with the potting 106 is similar to the sacrificial reactive layer 108 that is placed on the coil 124 as described below.

[0022] The sacrificial reactive layer 108 is made of one or more materials that have a high affinity to react with ammonia. Some materials for the sacrificial reactive layer 108 include zinc, copper, magnesium, or tin, to name a few examples. Other materials for the sacrificial reactive layer 108 can include non-magnetic metals to avoid altering the magnetic field producedWWD Ref: XS-3724Aty Docket No 11320-00930by the coil 124. In an ammonia environment wherein ammonia fuel is used as a fuel source and SOGAVs must be compatible with the ammonia, the sacrificial reactive layer 108 is configured as a means of mitigating ammonia attack on the coil 124 including the coil wire 112 and insulation layer 114. The sacrificial reactive layer 108 also mitigates ammonia attack on the coil 124 if the potting 106 develops cracks and no longer seals the coil 124. If cracks develop and propagate within the potting 106, then these cracks are a leak path for ammonia fuel to potentially access the coil 124. Additionally in this situation, the laminations 128 in the stator 126 can also receive the ammonia fuel to become a leak path to the coil 124 and thereby damage the coil 124. The sacrificial reactive layer 108 mitigates ammonia attack on the coil 124 in any of these potential situations.

[0023] In one embodiment, the sacrificial reactive layer 108 is configured as zinc foil and placed around the outside or outer surface 125 of the coil 124 to provide a sacrificial shield that protects the coil 124 from ammonia attack By placing the sacrificial reactive layer 108 with a high affinity to react with ammonia in close proximity to the coil 124, the ammonia will react with the sacrificial reactive layer 108 to consume the ammonia and form an inert byproduct such as zinc amine complex in the presence of the zinc foil. As a result of the ammonia being consumed by the reaction, a local ammonia-depleted environment is created in the region around the sacrificial reactive layer 108 and the coil 124, thereby mitigating ammonia attack on the wire 112 and the insulation 114 used in the coil 124. The wire 112 is typically made of material that would be subject to ammonia attack. One example material is copper for the wire 112. The insulation 114 is typically made of material that would be subject to ammonia attack and become brittle and / or crack which leads to degradation of the SOGAV performance. One example material is polymer for the insulation 114. The sacrificial reactive layer 108 assembled with the sacrificial reactive element coil assembly 100 allows the wires 112 and the insulation 114 made of susceptible material that are optimal from the standpoint of magnetic performance, manufacturability, commercial availability, and cost, and that would not otherwise survive in ammonia, to be used in ammonia environments.

[0024] In the illustrated embodiment in FIGS. 1 and 2, the sacrificial reactive layer 108 has a length sufficient to wrap around the coil 124. The length of the sacrificial reactive layer 108 can be sufficient to overlap itself, i.e., a first end covers an opposite second end, to form an overlap region 160 as the sacrificial reactive layer 108 is placed or wrapped around the coil 124.WWD Ref: XS-3724Aty Docket No 11320-00930The overlap region 160 of the sacrificial reactive layer 108 is illustrated in FIG. 2 and may vary in length from that illustrated in other embodiments. In FIG. 3, the sacrificial reactive layer 108 is located between the coil 124 and the potting 106 that is located between the sidewall of sleeve 102 and the coil 124. In an assembled configuration, the sacrificial reactive layer 108 has a height H that spans across the coil 124 to fully cover the coil 124. The sacrificial reactive layer 108 has a thickness that is constant and does not interfere with operation of the solenoid. For example, in one embodiment the thickness of the sacrificial reactive layer 108 is about 0.008” or about 0.20 millimeters. In other embodiments, the length, the thickness, and the height H, are different for the sacrificial reactive layer 108. For example, the length of the sacrificial reactive layer 108 may not be long enough to wrap entirely around the coil 124 such that a portion of the coil 124 is not covered by the sacrificial reactive layer 108. As another example, the height H of the sacrificial reactive layer 108 may be shorter or smaller such that the sacrificial reactive layer 108 does not entirely cover the coil 124. The sacrificial reactive layer 108 protects the coil 124 from ammonia degradation because the sacrificial reactive layer 108 is placed in close proximity to the windings of the coil 124.

[0025] The sacrificial reactive layer 108 does not necessarily need to seal or completely encase or cover the coil 124. The sacrificial reactive layer 108 can be configured differently in other embodiments. For example, the sacrificial reactive layer 108 can be embedded between the windings of the coil 124. As another example, the sacrificial reactive layer 108 can be embedded in the insulation 114. As another example, the sacrificial reactive layer 108 can be incorporated or embedded in the potting 106.

[0026] The sacrificial reactive layer 108 is configured to last or endure for the life expectation of the SOGAV in an ammonia environment. For example, if the life expectation of the SOGAV is 20,000 hours of operation then the life expectation of the sacrificial reactive layer 108 is the same or substantially the same as the SOGAV. An exemplary fuel source includes anhydrous ammonia for use with the sacrificial reactive element coil assembly 100.

[0027] FIG. 3 schematically illustrates the sacrificial reactive element coil assembly 100 mounted on the stator 126 used with the SOGAV solenoid 500. In the embodiment wherein the sacrificial reactive element coil assembly 100 includes the retention latches 122, the retention latches 122 would extend to the top edge of the stator 126 and would latch over the edge thereofWWD Ref: XS-3724Aty Docket No 11320-00930to hold the sacrificial reactive element coil assembly 100 in place to aid in further assembly of the SOGAV solenoid 500.

[0028] FIG. 4 illustrates an exemplary embodiment of the stator 126 that includes a plurality of legs or laminations 128 stacked together. Other embodiments of the stator 126 could be round and / or a solid stator and the sacrificial reactive element coil assembly 100 would correspondingly comply with this geometry.

[0029] As is evident from the figures and text presented above, a variety of aspects of the present disclosure are contemplated.

[0030] Various aspects of the present application are contemplated. According to one aspect, a sacrificial reactive element coil assembly for use in an electromagnetic device in an ammonia environment, the sacrificial reactive element coil assembly comprising: a bobbin; a coil wound on the bobbin; a sacrificial reactive layer configured to mitigate ammonia attack on the coil, wherein the sacrificial reactive layer is assembled with the coil; and a barrier provided around the sacrificial reactive layer to accommodate the bobbin, the coil, and the sacrificial reactive layer.

[0031] In one embodiment, the barrier includes a potting.

[0032] In one embodiment, the potting includes a sacrificial reactive material.

[0033] In one embodiment, the barrier includes a sleeve.

[0034] In one embodiment, the sacrificial reactive layer is made of any of zinc, copper, magnesium, and / or tin.

[0035] In one embodiment, the sacrificial reactive layer has a first end opposite a second end and a length that spans between the first and the second ends, wherein the sacrificial reactive layer wraps around an outer surface of the coil.

[0036] In one embodiment, the sacrificial reactive layer is made of zinc.

[0037] In one embodiment, the first end covers the second end to form an overlap region of the sacrificial reactive layer.

[0038] In one embodiment, wherein the sacrificial reactive layer does not cover a portion of the coil.

[0039] In one embodiment, the sacrificial reactive layer has a thickness of about 0.20 mm.WWD Ref: XS-3724Aty Docket No 11320-00930

[0040] According to another aspect, a sacrificial reactive element coil assembly for use in an electromagnetic device in an ammonia environment, the sacrificial reactive element coil assembly comprising: a bobbin; a coil assembled with the bobbin; a sacrificial reactive layer configured to mitigate ammonia attack on the coil, wherein the sacrificial reactive layer is positioned near the coil; and a barrier configured to accommodate the bobbin, the coil, and the sacrificial reactive layer therewithin.

[0041] In one embodiment, the coil includes one or more windings and the sacrificial reactive layer is embedded between at least one of the windings of the coil.

[0042] In one embodiment, further comprising an insulation layer that surrounds the coil, wherein the sacrificial reactive layer is embedded in the insulation layer.

[0043] In one embodiment, the sacrificial reactive layer is embedded in the barrier.

[0044] In one embodiment, the barrier includes a sleeve.

[0045] In one embodiment, the barrier includes a potting.

[0046] In one embodiment, the sacrificial reactive layer is made of any of zinc, copper, magnesium, and / or tin.

[0047] In one embodiment, the sacrificial reactive layer has a thickness that is constant.

[0048] In one embodiment, the sacrificial reactive layer has a first end opposite a second end and a length that spans between the first and the second ends, wherein the sacrificial reactive layer wraps around an outer surface of the coil that is assembled with the bobbin.

[0049] In one embodiment, the sacrificial reactive layer is made of zinc.

[0050] In the above description, certain relative terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “proximal,” “distal,” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and / or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object.

[0051] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the sameWWD Ref: XS-3724Aty Docket No 11320-00930embodiment. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more embodiments.

[0052] The described features, structures, advantages, and / or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and / or methods of a particular embodiment or implementation. In some instances, the benefit of simplicity may provide operational and economic benefits and exclusion of certain elements described herein is contemplated as within the scope of the invention herein by the inventors to achieve such benefits. In other instances, additional features and advantages may be recognized in certain embodiments and / or implementations that may not be present in all embodiments or implementations. Further, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.

[0053] The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

WWD Ref: XS-3724Aty Docket No 11320-00930 What is claimed is:

1. A sacrificial reactive element coil assembly for use in an electromagnetic device in an ammonia environment, the sacrificial reactive element coil assembly comprising:a bobbin;a coil wound on the bobbin;a sacrificial reactive layer configured to mitigate ammonia attack on the coil, wherein the sacrificial reactive layer is assembled with the coil; anda barrier provided around the sacrificial reactive layer to accommodate the bobbin, the coil, and the sacrificial reactive layer.

2. The sacrificial reactive element coil assembly of claim 1, wherein the barrier includes a potting.

3. The sacrificial reactive element coil assembly of claim 1, wherein the potting includes a sacrificial reactive material.

4. The sacrificial reactive element coil assembly of claim 1, wherein the barrier includes a sleeve.

5. The sacrificial reactive element coil assembly of claim 1, wherein the sacrificial reactive layer is made of any of zinc, copper, magnesium, and / or tin.

6. The sacrificial reactive element coil assembly of claim 1, wherein the sacrificial reactive layer has a first end opposite a second end and a length that spans between the first and the second ends, wherein the sacrificial reactive layer wraps around an outer surface of the coil.

7. The sacrificial reactive element coil assembly of claim 6, wherein the sacrificial reactive layer is made of zinc.

8. The sacrificial reactive element coil assembly of claim 6, wherein the first end covers the second end to form an overlap region of the sacrificial reactive layer.

9. The sacrificial reactive element coil assembly of claim 6, wherein the sacrificial reactive layer does not cover a portion of the coil.

10. The sacrificial reactive element coil assembly of claim 1, wherein the sacrificial reactive layer has a thickness of about 0.20 mm.

11. A sacrificial reactive element coil assembly for use in an electromagnetic device in an ammonia environment, the sacrificial reactive element coil assembly comprising:a bobbin;WWD Ref: XS-3724Aty Docket No 11320-00930a coil assembled with the bobbin;a sacrificial reactive layer configured to mitigate ammonia attack on the coil, wherein the sacrificial reactive layer is positioned near the coil; anda barrier configured to accommodate the bobbin, the coil, and the sacrificial reactive layer therewithin.

12. The sacrificial reactive element coil assembly of claim 11, wherein the coil includes one or more windings and the sacrificial reactive layer is embedded between at least one of the windings of the coil.

13. The sacrificial reactive element coil assembly of claim 11, further comprising: an insulation layer that surrounds the coil, wherein the sacrificial reactive layer is embedded in the insulation layer.

14. The sacrificial reactive element coil assembly of claim 11, wherein the sacrificial reactive layer is embedded in the barrier.

15. The sacrificial reactive element coil assembly of claim 14, wherein the barrier includes a sleeve.

16. The sacrificial reactive element coil assembly of claim 14, wherein the barrier includes a potting.

17. The sacrificial reactive element coil assembly of claim 11, wherein the sacrificial reactive layer is made of any of zinc, copper, magnesium, and / or tin.

18. The sacrificial reactive element coil assembly of claim 11, wherein the sacrificial reactive layer has a thickness that is constant.

19. The sacrificial reactive element coil assembly of claim 11, wherein the sacrificial reactive layer has a first end opposite a second end and a length that spans between the first and the second ends, wherein the sacrificial reactive layer wraps around an outer surface of the coil that is assembled with the bobbin.

20. The sacrificial reactive element coil assembly of claim 19, wherein the sacrificial reactive layer is made of zinc.

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