Solenoid activated exhaust gas recirculation valve

A valve actuator assembly comprising:

• (a) a bobbin defining a coil region;
• (b) a conductive coil disposed in the coil region for generating a magnetic field to actuate axial movement of a plunger through a plunger region defined in relation to the bobbin;
• (c) a magnetic pole piece inserted in the plunger region and having an inner region coaxially aligned with the plunger region along an axial extent of the plunger region;
• and
• (d) a molding formed around the bobbin such that the molding in combination with the bobbin encapsulate the conductive coil in the coil region, the molding fixing the magnetic pole piece in relation to the bobbin and extending over at least a portion of one end of the inner region of the magnetic pole piece.

A method for fabricating a valve actuator assembly comprising the steps of:

• (a) winding a conductive coil in a coil region of a bobbin, the conductive coil for generating a magnetic field to actuate axial movement of a plunger through a plunger region defined in relation to the bobbin;
• (b) forming a molding around the bobbin such that the molding in combination with the bobbin encapsulate the conductive coil in the coil region and such that the molding extends over at least a portion of one end of the plunger region and defines a cavity at the one end of the plunger region;
• and
• (c) inserting a position sensor in the cavity defined by the molding, the position sensor supported in the cavity for sensing a relative position of the plunger in the plunger region.

A method for fabricating a valve actuator assembly comprising the steps of:

• (a) winding a conductive coil in a coil region of a bobbin, the conductive coil for generating a magnetic field to actuate axial movement of a plunger through a plunger region defined in relation to the bobbin;
• (b) inserting in the plunger region a magnetic pole piece having an inner region coaxially aligned with the plunger region along an axial extent of the plunger region;
• and
• (c) forming a molding around the bobbin such that the molding in combination with the bobbin encapsulate the conductive coil in the coil region, such that the molding fixes the magnetic pole piece in relation to the bobbin, and such that the molding extends over at least a portion of one end of the inner region of the magnetic pole piece.