Delphi Technologies, Inc.

Omar Rocha

Alejandro Moreno

Jeffrey Heinrichs

Keith B Fong

Javier Gomez

Veronica Morales

A solenoid coil assembly having a first component member that is configured to support a coil and has a pair of terminal pins. The terminal pins are positioned for attachment to a structure such as a circuit board or lead frame. The first component member has pins for ultrasonic staking to a second component member. The second component member covers the first component member and the first and second component members provide an area for receiving and mounting the solenoid coil assembly to a valve assembly. The solenoid coil assembly positions first component member including the coil about the valve assembly.

Solenoid coil positioning assembly and method

A uniformly preset spring force pre-load among a number of identical solenoid actuated valve assemblies ( ) by uniquely adjusting the spring pocket length (L) of each respective plunger ( ) to accommodate a respective spring ( ) which is uniquely mated thereto. This adjustment is accomplished using a two-component plunger ( ) consisting of a plunger body ( ) having a central bore ( ) and a rod ( ) slidably located within the central bore. The rod ( ) is press-fit into the central bore ( ), and the spring pocket includes a portion of the central bore unoccupied by the rod. By pressing the rod ( ) a selected distance into the central bore ( ), a precisely set spring pocket is obtained which is uniquely correct for a selected spring ( ), in that the selected spring is compressed to a precisely preset spring force pre-load. The adjusted plunger ( ) and spring ( ) are uniquely assigned to each other to collectively form a customized plunger assembly ( ) having a preset spring force pre-load, whereupon a valve assembly ( ) is manufacturable therewith having the precisely preset spring force pre-load. In carrying-out the adjustment of the plunger ( ) with respect to a specific spring ( ), the rod is pressed into the bore by a controllable source of force, such as for example provided by a stepper motor ( ), and the spring force pre-load is monitored by a load cell ( ) to ascertain when the desired spring force pre-load is achieved. Monitoring and force control is preferably automatic via a micro-controller ( ), but may be manual.

Plunger assembly having a preset spring force pre-load

A coil assembly includes a spool ( ) having an upper flange ( ), a medial flange ( ) and a lower flange ( ). A terminal groove ( ) is established between the upper flange ( ) and the medial flange ( ), and a winding bay ( ) is established between the medial flange ( ) and the lower flange ( ). Ramps ( ) are formed in the groove ( ) and at least two terminal posts ( ), each having a foot ( ), are inserted through the upper flange such that each foot ( ) is disposed within the groove ( ). Each terminal post ( ) is movable between a winding position, wherein the foot ( ) protrudes outwardly to facilitate engaging a coil wire end ( ), and a retracted position, wherein the foot ( ) is retracted behind the respective ramp ( ).

Growing community of inventors

Juarez, Mexico

Omar Rocha