Solenoid valve and method for making same

A valve comprising a bobbin/valve body, a solenoid, and a plunger, wherein:

• the bobbin/valve body is formed in one piece and defines a plurality of ports, a longitudinal bore, and respective passageways between the longitudinal bore and the ports;
• the plurality of ports including a first port and a second port which both extend radially outward from the longitudinal bore in the same direction;
• the bobbin/valve having a central section at least partially defining the longitudinal bore;
• the solenoid being selectively energizable to produce a magnetic field and including a coil wrapped around the central section of the bobbin/valve body;
• the plunger includes a plunger body which moves within the bore in response to energization/deenergization of the solenoid between a first position whereat the passageway to the first port is sealed from the longitudinal bore and a second position whereat the passageway to the first port communicates with the longitudinal bore, and bottom walls of the bobbin/valve body defining a mounting surface of the valve which is flat except for port nipples extending perpendicular therefrom.

A method of making a valve comprising the steps of:

• forming a bobbin/valve body, unitary, in one piece, including ports, a longitudinal bore, and passageways between the longitudinal bore and the ports;
• inserting a plunger body through an end opening in the bobbin/valve body into the longitudinal bore;
• inserting a pole piece through the end opening in the bobbin/valve body into the longitudinal bore, wherein the pole piece includes an inclined annular tab;
• mating the tab with interior walls defining the longitudinal bore of the bobbin/valve body, thereby press-fit coupling the pole piece to the bobbin/valve body such that a fluid-tight seal is provided between the pole piece and the bobbin/valve body without additional mechanical coupling elements.

A method of making a valve comprising the steps of:

• forming a bobbin/valve body, unitary, in one piece, including ports, a longitudinal bore, and passageways between the longitudinal bore and the ports;
• inserting a plunger body through an end opening in the bobbin/valve body into the longitudinal bore;
• inserting a pole piece through the end opening in the bobbin/valve body into the longitudinal bore;
• and
• press-fit coupling the pole piece to the bobbin/valve body such that a fluid-tight seal is provided between the role piece and the bobbin/valve body without additional mechanical coupling elements;
• and further including a flux conductor magnetically coupling the bobbin/valve body to the pole piece, the flux conductor having a top portion and a pair of end portions, formed unitary with said top portion, and coupling one of said end portions of the flux conductor to the bobbin/valve body, and swage coupling the other of said end portions to a distal end of the pole piece.

A valve comprising a bobbin/valve body, a solenoid, and a plunger, wherein:

• the bobbin/valve body is formed in one piece and defines a plurality of ports, a longitudinal bore, and respective passageways between the longitudinal bore and the ports;
• the plurality of ports including a first port and a second port which both extend radially outward from the longitudinal bore in the same direction;
• the bobbin/valve having a central section at least partially defining the longitudinal bore;
• the solenoid including a pole piece positioned within the longitudinal bore, the solenoid being selectively energizable to produce a magnetic field and including a coil wrapped around the central section of the bobbin/valve body;
• the plunger includes a plunger body which moves within the bore in response to energization/deenergization of the solenoid between a first position whereat the passageway to the first port is sealed from the longitudinal bore and a second position whereat the passageway to the first port communicates with the longitudinal bore, wherein the pole piece includes an inclined annular tab with mates within interior walls of the longitudinal bore such that the pole piece is press-fit within the longitudinal bore of the bobbin/valve body.

A valve comprising a bobbin/valve body, a solenoid, and a plunger, wherein:

• the bobbin/valve body is formed in one piece and defines a plurality of ports, a longitudinal bore, and respective passageways between the longitudinal bore and the ports;
• the plurality of ports including a first port and a second port which both extend radially outward from the longitudinal bore in the same direction;
• the bobbin/valve having a central section between the first and second ports and at least partially defining the longitudinal bore;
• the solenoid being selectively energizable to produce a magnetic field and including a coil wrapped around the central section of the bobbin/valve body;
• the plunger includes a plunger body which moves within the bore in response to energization/deenergization of the solenoid between a first position whereat the passageway to the first port is sealed from the longitudinal bore and a second position whereat the passageway to the first port communicates with the longitudinal bore.

A valve comprising a bobbin/valve body, a solenoid, and a plunger, wherein:

• the bobbin/valve body is formed in one piece and defines a plurality of ports, a longitudinal bore, and respective passageways between the longitudinal bore and the ports;
• the plurality of ports including a first port and a second port which both extend radially outward from the longitudinal bore in the same direction;
• the bobbin/valve having a central section at least partially defining the longitudinal bore;
• the solenoid including a pole piece positioned within the longitudinal bore, the solenoid being selectively energizable to produce a magnetic field and including a coil wrapped around the central section of the bobbin/valve body;
• the plunger includes a plunger body which moves within the bore in response to energization/deenergization of the solenoid between a first position whereat the passageway to the first port is sealed from the longitudinal bore and a second position whereat the passageway to the first port communicates with the longitudinal bore, and further including a flux conductor magnetically coupling the bobbin/valve body to the pole piece, the flux conductor having a top portion and a pair of end portions, formed unitary with the top portion, and coupling one of said end portions of the flux conductor to the bobbin/valve body, and the other of said end portions being swage coupled to a distal end of the pole piece.