Magnetic Fluid Valve Overmolded Core for Calibration-Free Switching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fluid valves with magnetic drives are complex and expensive to produce, requiring calibration of armature positions for defined closing behavior, which increases costs.
Innovation Solution
A fluid valve with a drive unit featuring a core, electrical coil, and armature, where the core is fixed in a defined position via overmolding, allowing precise manufacturing and eliminating the need for final adjustment, using a U-shaped core and layered metallic flat material for cost-effective production and enhanced magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods with adjustable stops are used, then the valve closing behavior can be calibrated, but the manufacturing complexity and cost increase
Solution Approach 1:
The core insertion position is predetermined and fixed during the overmolding process itself, rather than requiring subsequent adjustment. The molding tool defines the exact insertion position of the core in the base body, ensuring precise pole face positioning relative to the armature receptacle before final assembly occurs.
Solution Approach 2:
The overmolding process automatically secures the core in the correct position through the molding tool's design, eliminating the need for external calibration devices or adjustment mechanisms. The system self-configures the core position during manufacturing, reducing both complexity and cost.
2Reliability
If adjustable stops are used for armature positioning, then defined closing behavior is achieved, but production time and cost increase
Solution Approach 1:
The core is positioned and secured in its final, correct location during the overmolding process itself. The molding tool ensures that the core assumes a defined insertion position relative to the armature receptacle, eliminating the need for subsequent adjustment operations and enabling immediate assembly of complete units.
Solution Approach 2:
The mechanical adjustment mechanism (stops) is replaced by a molded-in positioning system. The overmolding process creates integral positioning features that guide and secure the core, substituting complex mechanical adjustment with a simpler, more efficient molding-based solution.
3Manufacturing precision
If core position adjustment is required after assembly, then precise positioning is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The core positioning function is merged with the base body structure through the overmolding process. The molding material integrates the core securing mechanism directly into the base body, creating a unified component that eliminates separate positioning devices and simplifies the overall manufacturing process.
Solution Approach 2:
The core is positioned and secured in its final, correct location during the overmolding process itself. The molding tool ensures that the core assumes a defined insertion position relative to the armature receptacle, eliminating the need for subsequent adjustment operations and enabling immediate assembly of complete units.
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
Simplifies the manufacturing process, reduces production costs, and ensures a defined switching behavior without readjustment, achieving precise positioning and high actuating force with a closed magnetic circuit.
Implementation Method 1
The drive unit has a core, an electrical coil partially surrounding the core, and an armature movable by energizing the coil and the resulting magnetic force
Implementation Method 2
an armature movable by energizing the coil and the resulting magnetic force
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a fluid valve comprising a drive unit (2) for a valve closing element, wherein the drive unit (2) has a core (3), an electrical coil (4) partially surrounding the core (3) and an armature (5) movable by the energization of the coil (4) and the resulting magnetic force, wherein the drive unit (2) has a base body (6) on which a receptacle (6.1) for the coil (4), at least one insertion opening (6.2) for the core (3) and an armature receptacle (6.3) are provided, and wherein the core (3) inserted into the at least one insertion opening (6.2) is fixed to the base body (6) by means of an overmolding (7) such that the core (3) assumes a defined position relative to the armature receptacle (6.3).