Integrated Water-Isolating Stator Assembly for Stronger Solenoid Valves
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Solution Overview
Problem
The existing solenoid valves for water require a separate manufacturing process for the water-isolating sleeve, leading to increased costs and structural damage risks due to the need for a thicker sleeve to withstand pressure, and the welding process further complicates assembly, necessitating more electromagnetic force and higher copper wire usage.
Innovation Solution
The method involves forming a stator assembly with a water-isolating sleeve by injecting plastic into the coil assembly, which includes upper and lower magnetic conductive inner sleeves, reducing the thickness of the sleeve and simplifying the manufacturing process by integrating the yoke and coil assembly with plastic, thereby enhancing electromagnetic force and reducing copper wire consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate water-isolating sleeve is manufactured and assembled, then the valve can withstand pressure impact, but the sleeve thickness increases leading to greater non-working air gap and reduced electromagnetic force
Solution Approach 1:
The water-isolating sleeve is integrated directly into the coil rack structure, eliminating the separate assembly step. This merging of functions allows the sleeve to be formed as part of the magnetic conductive inner sleeve, reducing total thickness while maintaining pressure resistance through optimized material properties and structural design.
Solution Approach 2:
The patent employs a thin-walled water-isolating sleeve formed by injection molding, which provides sufficient pressure resistance through its material composition and structural design rather than relying on thickness. This thin-film approach reduces the non-working air gap from over 1.5mm to under 1mm, significantly improving electromagnetic force.
2Strength
If a thicker water-isolating sleeve is used to withstand pressure, then structural integrity is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The water-isolating sleeve and coil rack are combined into a single integrated component manufactured through injection molding. This eliminates separate manufacturing and assembly steps, reducing labor costs and assembly complexity while maintaining structural integrity through design optimization rather than increased thickness.
Solution Approach 2:
The mechanical assembly process for installing a separate water-isolating sleeve is replaced with a single injection molding process that forms the sleeve as an integral part of the coil rack. This substitution of manufacturing methodology reduces both cost and complexity while achieving the same structural integrity function.
3Stability of the object's composition
If the yoke is welded to the magnetic conductive inner sleeve, then the yoke is fixed to the coil rack, but the welding process increases manufacturing cost and complexity
Solution Approach 1:
The welding process is replaced with a mechanical insertion method where the yoke is directly inserted into a positioning structure on the coil rack. This substitution eliminates the welding operation, reducing manufacturing cost and complexity while maintaining stable fixation through precision mechanical interference fit.
Solution Approach 2:
The welding operation is extracted and removed from the manufacturing process entirely. The fixation function is achieved through a purely mechanical insertion method, simplifying the process while maintaining the stability of yoke attachment to the coil rack.
4Force
If more copper wire is used, then electromagnetic force is sufficient, but material cost increases
Solution Approach 1:
The non-working air gap parameter is changed from over 1.5mm to under 1mm by reducing water-isolating sleeve thickness. This parameter change increases magnetic flux density and electromagnetic force, allowing for reduced copper wire consumption while maintaining sufficient electromagnetic attraction force for valve operation.
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
This approach enhances the electromagnetic suction force, improves the solenoid valve's low-pressure activation performance, reduces production costs, and simplifies the manufacturing process while maintaining performance levels.
Implementation Method 1
When the winding 109 is energized, the magnetic attraction draws the movable iron core 201 up
Implementation Method 2
a magnetic yoke 111 mounted on the outside of the plastic sealed layer, an upper magnetic conductive inner sleeve 113 and a lower magnetic conductive inner sleeve 114
Data Source
AI summary
The present invention discloses a stator assembly with water-isolating sleeve applied to solenoid valve for water and implementation method thereof, the implementation method comprising: forming a coil assembly with a cavity by installing an element including an insert on a coil rack wound with a coil winding; forming a stator assembly by installing an upper magnetic conductive inner sleeve and a lower magnetic conductive inner sleeve at both sides in a holein the coil rack of the coil assembly, and fixing the yoke connecting the upper magnetic conductive inner sleeve and the lower magnetic conductive inner sleeve outside the coil assembly; injecting plastic on the stator assembly to form the stator assembly with water-isolating sleeve.