Elastomeric Biasing Member for Solenoid Insulation
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Solution Overview
Problem
There is a need for a small, compact, and inexpensive solenoid suitable for low horsepower internal combustion engine applications that can withstand severe weather conditions and high levels of vibration and shock, while minimizing parts for cost-effectiveness and durability.
Innovation Solution
A solenoid design featuring a hollow open-ended housing with a coil assembly, a bobbin, armature, and flux washer, along with a non-metallic insulative biasing member and a sealing gasket, which helps in retaining the coil assembly and reducing electrical conduction to the mounting object, ensuring compactness and ruggedness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a solenoid is designed to be compact and inexpensive for low horsepower engine applications, then cost and space requirements are met, but durability and reliability under severe weather conditions and high vibration/shock levels deteriorate
Solution Approach 1:
The patent combines multiple functions into the elastomeric biasing member: it provides mechanical biasing force, electrical insulation, magnetic flux conduction path, and sealing support. This integration reduces part count and assembly complexity while maintaining reliability, as the single elastomeric component eliminates interfaces between multiple parts that could fail under vibration and shock conditions
Solution Approach 2:
The patent employs an elastomeric material with specific properties (conductivity 10^-6 to 10^2 mhos per inch, durometer 20-90) that combines electrical insulating characteristics with magnetic flux conduction capability. This composite material approach allows the biasing member to simultaneously provide mechanical biasing, electrical isolation, and magnetic circuit completion, achieving both compactness and durability
2Ease of manufacture
If fewer parts are used in solenoid construction to reduce cost and improve manufacturing consistency, then manufacturing quality improves, but functional complexity of each remaining part must increase
Solution Approach 1:
The elastomeric biasing member is designed as a universal component that performs multiple critical functions: providing biasing force against the armature, electrically insulating the bobbin projection from the mounting plate, conducting magnetic flux from the flux washer to the mounting plate, and supporting the sealing gasket. This multi-functionality reduces the total part count while maintaining all necessary solenoid functions, improving manufacturing consistency by reducing assembly steps and potential failure points
3Volume of moving object
If the solenoid is made compact for confined engine compartment space, then space requirements are met, but thermal management and cooling become more difficult
Solution Approach 1:
The elastomeric biasing member acts as a thermal intermediary between the coil assembly and the mounting plate. While providing electrical insulation, the elastomeric material with its specific thermal properties facilitates controlled heat dissipation from the compact coil assembly to the mounting plate structure, enabling thermal management in the confined solenoid volume without requiring additional cooling components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solenoid achieves economic durability and reduced failure rates by maintaining performance while being compact and cost-effective, with the insulative biasing member enhancing magnetic flux efficiency and preventing electrical shorts.
Implementation Method 1
a biasing member having a body with a first surface, a second surface opposite the first surface, a cavity extending inwardly from the first surface towards the second surface, and a leg extending outwardly from the body second surface
Implementation Method 2
a coil assembly housed in the housing comprising a cup-shaped can, a bobbin with a center tube and an outward projection extending outwardly coaxially from the center tube, an armature within the bobbin
Implementation Method 3
a flux washer abutting the open end of the cup-shaped can; the biasing member positioned between the mounting plate and the flux washer with the biasing member first surface abutting the flux washer
Implementation Method 4
a non-metallic insulative biasing member
Data Source
AI summary
An apparatus and method directed to the art of providing an electrically insulative electric solenoid for starting internal combustion engines are provided. The solenoid has a housing; a coil unit within the housing comprising a hollow can with an open end, and a bobbin, an armature, and a bridging contact assembly positioned in the can; a flux washer abutting the open end of the can; a mounting plate abutting the open end of the housing, and an electrically insulative biasing member positioned between the mounting plate and the flux washer and between the mounting plate and the bobbin.