Solenoid Valve Integrated Outer Case Assembly
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Solution Overview
Problem
Conventional solenoid valves require additional accessories for assembly, leading to size limitations, unstable quality, and poor roundness of valve orifices, resulting in fluid pressure leaks and inefficient fluid control.
Innovation Solution
A solenoid valve design featuring a main body with a bobbin, fixed and movable iron cores, a magnetic conductive portion, and an outer case, where the bobbin has a communication hole and the iron cores are oppositely disposed, along with a valve portion and covers, utilizing an insert molding method to ensure precise assembly and surface machining for improved fluid cutting capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If additional accessories are used for assembling conventional solenoid valves, then the assembly process can be completed, but the size of the solenoid valve cannot be miniaturized and manufacturing tolerances and clearances are introduced
Solution Approach 1:
The patent integrates multiple components into a unified structure where the outer case serves as both the housing and the assembly fixture. The bobbin is directly mounted on the valve body, and the coil is wound directly on the bobbin, eliminating the need for separate mounting accessories and reducing overall valve size while maintaining assembly precision.
Solution Approach 2:
The solenoid valve is divided into integrated modules: the outer case forms a complete assembly unit, the bobbin is a self-contained component with built-in mounting features, and the coil is pre-assembled on the bobbin. This modular segmentation allows for precise manufacturing of individual parts that assemble without additional accessories.
2Reliability
If additional accessories are required for assembly, then the valve can be constructed, but manufacturing tolerances and clearances are introduced causing unstable quality
Solution Approach 1:
By merging the outer case, bobbin, and coil into an integrated assembly where the outer case directly houses the bobbin and the coil is pre-mounted on the bobbin, the patent eliminates cumulative tolerance errors from multiple separate components. This reduces the number of interfaces and ensures consistent relative positions across production batches.
3Manufacturing precision
If conventional assembly methods are used, then the valve can be manufactured, but protrusions are caused at valve orifice resulting in poor roundness and fluid pressure leakage
Solution Approach 1:
The valve orifice surfaces are pre-polished to mirror finish before final assembly. The bobbin and valve body are precisely positioned and fixed during assembly, preventing any protrusion formation at the orifice. This preliminary surface preparation ensures high roundness and sealing quality without requiring complex post-assembly adjustments.
4Reliability
If relative locations among main functional elements change with different production batches, then manufacturing flexibility is maintained, but the quality becomes unstable
Solution Approach 1:
The outer case is designed as a complete assembly unit that integrates the housing, mounting features, and positioning structures. The bobbin is directly mounted on the valve body with fixed positioning, and the coil is pre-assembled on the bobbin. This merged structure ensures that relative positions of all functional elements remain constant across production batches, eliminating quality variability.
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
The solution stabilizes the solenoid valve's dimensions and performance, allowing for precise control and quick fluid cutting, eliminating the need for additional assembly parts and ensuring consistent quality across production batches.
Implementation Method 1
a coil and an outer case, wherein the bobbin has a first terminal, a second terminal, a middle portion and a communication hole... the coil is wound on the bobbin
Implementation Method 2
the magnetic conductive portion is disposed in the communication hole and disposed at the second terminal, wherein the magnetic conductive portion and the fixed iron core are disposed oppositely
Data Source
AI summary
A solenoid valve and a manufacturing method are disclosed. The solenoid valve includes a main body portion, a movable iron core, a valve portion, a lower cover and an upper cover. Wherein the main body portion includes a bobbin, a fixed iron core, a magnetic conductive portion, a coil and an outer case. The outer case covers the bobbin, the fixed iron core, the magnetic conductive portion, and the coil. The movable iron core is movable relative to the fixed iron core, and the lower cover is disposed in the valve portion. A left side surface of the upper cover is fixed at the valve portion and the lower cover, and a right side surface of the upper covers is fixed at the main body portion. The solenoid valve has stable size and stable operation, and can quickly cut off the air pressure, and the control effect is good.