Interlocking Flux Collector Segments for Solenoid Valve

Solution Overview

Problem

Solenoid valves with integral flux collectors are costly and limit design flexibility, as the flux collector must be cast together with the valve body, restricting manufacturing processes and potential configurations.

Innovation Solution

A solenoid valve assembly featuring a substantially annular flux collector formed by interlocking arced portions that can be separately manufactured and inserted into a groove on the valve body, allowing for a turned valve body and enabling independent manufacturing of the flux collector.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the flux collector is cast integrally with the valve body, then the structural strength and reliability are improved, but the manufacturing cost increases and design flexibility is limited

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The flux collector is divided into separate arced portions that can be manufactured independently and then assembled together to form the complete annular flux collector. This segmentation allows each portion to be produced using cost-effective manufacturing processes while maintaining the structural integrity and magnetic flux collection functionality of the complete assembly.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If the flux collector is cast integrally with the valve body, then the structural integrity is improved, but the design flexibility and manufacturing process options are reduced

Engineering Contradiction:

Improvestructural integrityVSAvoiddesign flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The flux collector is divided into separate arced portions that can be manufactured independently and then assembled together to form the complete annular flux collector. This segmentation allows each portion to be produced using cost-effective manufacturing processes while maintaining the structural integrity and magnetic flux collection functionality of the complete assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separate arced portions of the flux collector are designed to fit together like nested segments, with each portion containing features such as slots and protrusions that enable precise interlocking. This nesting approach allows the separate portions to be assembled into a complete annular structure that maintains structural integrity comparable to an integrally cast flux collector.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If the flux collector is made as separate interlocking portions, then the manufacturing cost and flexibility are improved, but the structural integrity compared to integral casting is reduced

Engineering Contradiction:

Improvemanufacturing costVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The separate arced portions of the flux collector are designed to fit together like nested segments, with each portion containing features such as slots and protrusions that enable precise interlocking. This nesting approach allows the separate portions to be assembled into a complete annular structure that maintains structural integrity comparable to an integrally cast flux collector.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The arced portions are pre-manufactured with precise interlocking features including slots and protrusions that are prepared in advance. This preliminary action ensures that when the portions are assembled, they form a structurally sound complete flux collector without requiring complex post-assembly operations, thereby maintaining structural integrity while benefiting from the manufacturing flexibility of separate production.

Inventive Principle:

Principle #10Preliminary action

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 design allows for a cost-effective and flexible manufacturing process, enabling precise positioning of the flux collector for enhanced magnetic field direction and improved armature movement responsiveness without the need for integral casting.

Implementation Method 1

a coil that can carry current to create an electromagnetic flux field, causing movement of an armature within the valve

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

Flux collectors are sometimes placed adjacent the coil around the armature to collect the flux, thereby directing the magnetic field to aid in movement of the armature

Methodology Applied

Scientific EffectMagnetic flux collection: Magnetic Field

Data Source

PatentUS9423046B2Flux collector with interconnected portions and method of manufacturing solenoid valve assembly having same

Publication Date: 2016.08.23 EATON INTELLIGENT POWER LTD

AI summary

An apparatus such as for a solenoid valve assembly includes a substantially annular flux collector (12) that has a first arced portion (10) and at least one additional arced portion (14). The first arced portion and the at least one additional arced portion are cooperatively configured to interlock with one another to form the substantially annular flux collector. A method (200) of manufacturing a solenoid valve assembly using the annular flux collector is also provided.