Solenoid And Method Of Manufacture
AssigneeRain Bird Corporation
InventorsKevin James Markley, Troy Lynn Roney, John James Wlassich, Randy Ray Montgomery, Chong Wang Kwak
Life of this patent
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Abstract
A solenoid is provided having an improved connection arrangement. The solenoid includes external wires that are coupled to internal solenoid components via terminals. Further, a sealed solenoid is provided having a housing overmolded onto a solenoid subassembly. External wires can be coupled to the solenoid after overmolding. The solenoid may also include a cavity for receiving at least one of electrical component. The solenoid may also include a powdered metal core.
Claims29
A solenoid comprising:
- a bobbin;
- a core wire positioned about at least a portion of the bobbin, the core wire forming a coil;
- a housing positioned about at least a portion of the coil;
- a lid coupled to the housing, the lid and housing defining an interior area;
- an external wire extending from outside the housing into the interior area;
- and
- a cavity positioned on the housing in the interior area, the cavity positioned adjacent the external wire and sized to accept at least one electrical component.
A method of forming a solenoid comprising the steps of:
- wrapping a wire around a bobbin to form a coil;
- inserting a core into an opening at a first end of the bobbin;
- positioning a cylinder about the coil and at least a portion of the bobbin, a gap being formed between the cylinder and the coil, the cylinder having an outer surface with at least one opening;
- overmolding a housing about the cylinder whereby material from the housing is permitted to enter the opening in the cylinder and substantially fill the gap between the cylinder and coil, the housing including a channel and a cavity on an external surface thereof;
- inserting an external wire into the channel such that the external wire extend from outside the housing into the channel;
- inserting at least one electrical component into the cavity;
- and
- securing a lid to the housing such that the lid and housing define an interior area about the channel and the cavity.
A solenoid comprising:
- a bobbin;
- a core wire positioned about at least a portion of the bobbin and forming a coil, the core wire having first and second terminal ends;
- a housing positioned about at least a portion of the core wire, the housing defining an opening providing access from an exterior side of the housing to the first terminal end;
- an external wire extending from outside the housing;
- and
- a wire-to-wire terminal having a first end extending at least partly into the opening in the housing providing contact with the first terminal end of the solenoid coil wire and a second end providing contact with the external wire, the wire-to-wire terminal providing an electrical connection between the first terminal end and the external wire.
A solenoid comprising:
- a bobbin having a body and a generally cylindrical opening at a first end extending into the body;
- a core wire positioned about at least a portion of the body and forming a coil, the core wire having first and second terminal ends;
- a powdered metal core having a flange portion integral with a core portion, the core portion extending at least partially into the cylindrical opening of the bobbin;
- and
- a housing positioned about at least a portion of the coil.
Dependencies are inferred from the claim text.