Over-molded Solenoid Core Alignment
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Solution Overview
Problem
Existing solenoid valves face inefficiencies due to misalignment of magnetic core and pole piece, leading to increased air-gaps and friction, which reduces magnetic flux efficiency and requires additional seals, making them costly and difficult to manufacture.
Innovation Solution
The solenoid employs an over-moulded bobbin component that aligns and maintains the magnetic core and pole piece coaxially, reducing air-gaps and eliminating the need for O-rings by molecular adhesion, thereby improving concentricity and fluid-tight sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate component assembly is used for magnetic core and pole piece, then manufacturing flexibility is maintained, but concentricity alignment deteriorates leading to increased air-gaps
Solution Approach 1:
The magnetic core and pole piece are merged into a single integrated component with a unified body structure. This integration eliminates the need for separate assembly operations and ensures perfect concentricity alignment between the core and pole piece, as they are manufactured as one piece. The unified design removes the alignment tolerances that would exist in separate component assemblies.
Solution Approach 2:
The integrated magnetic core and pole piece structure serves multiple functions simultaneously: it provides the magnetic flux path, acts as the structural support, and ensures precise concentric alignment. The single component design combines what were previously separate functional elements into one universal structure that performs all necessary roles.
2Ease of manufacture
If larger air-gaps are used to accommodate misalignment, then manufacturing tolerances are relaxed, but magnetic flux efficiency deteriorates
Solution Approach 1:
By merging the magnetic core and pole piece into one integrated component, the invention eliminates misalignment issues entirely. This allows for minimal air-gaps to be used, optimizing magnetic flux efficiency while maintaining ease of manufacture through the simplified single-component design.
3Reliability
If additional seals are added to prevent fluid leakage, then sealing reliability improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The integrated magnetic core and pole piece structure eliminates the need for separate seals at the interface between these components. By combining them into one piece, the potential leakage path is removed, achieving fluid-tight sealing without adding complex sealing components.
4Ease of manufacture
If multiple separate components are used, then assembly flexibility is maintained, but the number of seals and manufacturing steps increases
Solution Approach 1:
The invention merges multiple separate components (magnetic core and pole piece) into a single integrated structure. This reduction in component quantity simplifies the assembly process, eliminates the need for multiple seals, and reduces manufacturing complexity while maintaining all necessary functional capabilities.
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 magnetic flux alignment, reduces air-gaps, and minimizes manufacturing costs by maintaining precise alignment and eliminating the need for additional seals, resulting in improved solenoid efficiency and control.
Implementation Method 1
an electric current is applied to an electromagnetic coil, with the coil typically positioned around a magnetic core. The energized solenoid generates a magnetic field.
Implementation Method 2
the magnetic flux produced by the energized coil is shaped and directed by the magnetic core and a magnetic pole piece
Implementation Method 3
The solenoid employs an over-moulded bobbin component that aligns and maintains the magnetic core and pole piece coaxially, reducing air-gaps and eliminating the need for O-rings by molecular adhesion
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A solenoid (30) is provided. The solenoid (30) includes a magnetic core (304). The solenoid (30) also includes a pole piece (305) positioned substantially coaxially with the magnetic core (304). An over-molded component (303) is provided that is over-molded around at least a portion of the magnetic core (304) and at least a portion of the pole piece (305).