Solenoid coil for hazardous locations

A solenoid coil assembly configured to operate a valve assembly in a hazardous environment, comprising:

• a yoke having a base portion connected to two flange portions, the base portion and the two flange portions having a generally U-shaped profile;
• a bobbin mounted to the yoke, the bobbin having a tubular main body connected to a top plate and a bottom plate and configured to hold a coil of wire thereon;
• a protective housing enclosing the yoke and the bobbin, the protective housing having a plurality of generally rectangular side walls, a generally rectangular top wall, and a generally rectangular bottom wall, each of the generally rectangular top wall and the generally rectangular bottom wall having an annular opening therein for receiving the valve assembly;
• and
• encapsulation material disposed within the protective housing and surrounding the yoke and the bobbin, the encapsulation material filling the protective housing and preventing hazardous material from the hazardous environment from accumulating within the protective housing;
• wherein one or more walls of the protective housing is made of a corrosion resistant material and has a thickness that renders the protective housing non-compliant with at least one industry strength requirement for solenoid coil assemblies in the hazardous environment.

A method for preparing a solenoid coil assembly for operating a valve assembly in a hazardous environment, comprising:

• mounting a bobbin to a yoke;
• enclosing the bobbin and the yoke within a protective housing, the protective housing having a wire conduit integrally formed thereon;
• attaching a conduit sleeve to the wire conduit;
• and
• injecting an encapsulation material into the protective housing such that the encapsulation material fills the protective housing and the wire sleeve to form a zero-volume enclosure;
• wherein the zero-volume enclosure prevents hazardous material from the hazardous environment from accumulating within the protective housing.