Solenoid Valve Magnetic Core Thickness Distribution
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Solution Overview
Problem
Conventional solenoid valves face issues with reduced magnetic flux and attraction force due to thin protruding portions in the magnetic circuit, leading to operation failures and slow response, while thick magnetic cores result in large and heavy valves that contradict downsizing needs.
Innovation Solution
The solenoid valve design ensures the thickness of the peripheral wall portion of the fixed core near the bottom wall is 80% or more of the outer plate portion's thickness, achieved through a specialized drawing process where the flat steel plate is subjected to multiple drawing steps without clamping the unclamped portion, allowing material to flow and maintain a thick peripheral wall, thus reducing magnetic flux reduction and enhancing response properties without requiring thick steel plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a thick flat steel plate is used as a blank to form a protruding portion with sufficient thickness, then the solenoid part can generate large attraction force, but the solenoid valve becomes large in size and heavy in weight
Solution Approach 1:
The patent applies local quality by making the peripheral wall portion thickness non-uniform along the axial direction. Specifically, the thickness at the bottom wall portion (near the solenoid part) is maintained at 80% or more of the original plate thickness to ensure sufficient magnetic flux and attraction force, while the thickness at the distal end is reduced. This localized thickness distribution optimizes both magnetic performance and overall size/weight reduction.
2Reliability
If the protruding portion is made by deep drawing to reach about a middle portion of the solenoid part, then the magnetic circuit can be formed, but the distal end portion becomes thinner and magnetic flux decreases
Solution Approach 1:
The patent addresses this contradiction by implementing local quality control over the peripheral wall thickness. The thickness at the bottom wall portion (where the solenoid part is located) is specifically maintained at 80% or more of the original flat steel plate thickness, ensuring adequate magnetic flux generation and reliable operation. This localized thickness maintenance compensates for the thinning effect of deep drawing at other locations.
3Volume of moving object
If the thickness of the protruding portion is thin, then the solenoid valve can be downsized, but the cross-sectional area of the magnetic circuit decreases and magnetic flux allowed to pass through decreases
Solution Approach 1:
The patent resolves this contradiction through local quality optimization. By maintaining the peripheral wall portion thickness at 80% or more of the original thickness specifically at the bottom wall portion (where the solenoid part interfaces), the magnetic circuit retains sufficient cross-sectional area for adequate magnetic flux. This localized thickness control enables downsizing of non-critical areas while preserving magnetic performance in critical regions.
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 configuration maintains the solenoid valve's response property while downsizing the valve, as the magnetic flux and attraction force are preserved, and the thickness of the steel plate used can be reduced, meeting the need for compactness.
Implementation Method 1
a hollow cylindrical solenoid part (coil molded part) 20 containing a coil 23, and a magnetic core (upper core 10 and lower core 30) surrounding the coil molded part 20 to form a magnetic circuit
Implementation Method 2
a magnetic core is provided to form a magnetic circuit around a solenoid part, and a part of the magnetic core protrudes into the one end of the hollow portion of the solenoid part
Data Source
Figure 1
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AI summary
In a solenoid valve (1) including a hollow cylindrical coil molded part (20), a plunger (60), and a valve element (75), in which the plunger (60) is attracted upon energization of the coil molded part (20) to move the valve element (75), the solenoid valve further includes a magnetic core (an upper core (10) and lower core (30)) surrounding the coil molded part (20) to form a magnetic circuit, a part of the magnetic core protrudes into a hollow portion (24A) of the coil molded part (20) to form a hollow cylindrical protruding portion (12) provided with a bottom wall portion (12a) at a distal end, and the protruding portion (12) includes a peripheral wall portion (12b) having a thickness (W1) near the bottom wall portion (12a), the thickness (W1) being as thick as 80% or more of a thickness (W2) of an upper plate portion (11).