Remanufactured solenoid valves and devices for remanufacturing solenoid valves

#The present invention generally relates to the field of solenoid valves. In particular, the present invention is directed to remanufactured solenoid valves and devices for remanufacturing solenoid valves.

#Solenoid valves are electromechanically-operated valves that include at least one valve controlled by an electric current through a solenoid. Solenoid valves are ubiquitous in modern automobile transmissions and play critical roles in the proper functioning of the transmission. After prolonged use, however, the valve components in a solenoid valve may begin to wear, which can lead to fluid leakage, causing transmission components to not receive the correct amount of fluid flow and fluid pressure. Depending on the particular solenoid and the severity of the leakage, a malfunctioning solenoid can cause the transmission system to produce error codes, cause poor shift performance, cause the transmission to shift at incorrect times, or not shift at all. In some cases, it might be possible to repair a malfunctioning solenoid by refurbishing or replacing worn or malfunctioning components, however, solenoids are often encased in permanently-sealed housings making it difficult to perform the repair in a manner that allows reassembly and reuse of the solenoid. Thus, the only solution currently available for repairing a transmission with certain types of malfunctioning solenoids is to completely replace the solenoids rather than repair them.

#In one implementation, the present disclosure is directed to a brace for remanufacturing an original equipment (OE) solenoid valve, the OE solenoid valve having a solenoid portion and a valve portion, the valve portion configured and dimensioned to be sealingly disposed in a solenoid bore of a valve body, the valve portion including a valve housing having a substantially cylindrical outer surface, an exhaust portion defining a plurality of exhaust ports, and a substantially cylindrical cap defining a plurality of inlet ports and disposed over the valve housing. The brace includes a first portion having a central longitudinal axis and configured to be disposed on the outer surface of the valve housing and configured to prevent relative movement between the brace and the valve housing in a first direction along the central longitudinal axis; and a second portion configured to be coupled to at least one of the exhaust ports and configured to prevent relative movement between the brace and the solenoid portion in a second direction substantially opposite the first direction to thereby securely couple the valve housing to the exhaust portion.

#For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

#FIG. 1 is a hydraulic schematic of an exemplary prior art Original Equipment (OE) transmission having solenoid valves that may be remanufactured according to the present disclosure;

#FIG. 2 is a prior art OE solenoid valve from FIG. 1 disposed in a solenoid bore of a valve body;

#Aspects of the present disclosure are directed to systems and methods for remanufacturing solenoid valves that enable the repair, reassembly, and reuse of a solenoid. Such techniques and systems allow for a solenoid valve to be restored to proper working condition and avoids the need to completely replace the solenoid with what may be an expensive replacement component, thereby reducing costs associated with a transmission repair. Aspects of the present disclosure may also include a kit for remanufacturing a solenoid which may include a brace for securing a valve housing of a remanufactured solenoid that has been opened for repair.

#For the purposes of illustrating aspects of the invention, the present disclosure includes exemplary embodiments of methods and devices for remanufacturing solenoids. The present invention, however, is not limited to the specific embodiments disclosed and may be applied to a variety of solenoid valve types and a variety of different repairs that are not specifically disclosed. For example, the present disclosure includes exemplary methods and devices for repairing normally applied (“NA”), also referred to as “blue cap,” 6HP solenoids used in ZF (TM) transmissions, including 6HP19, 6HP21, 6HP26, 6HP28, 6HP32, and 6HP34 model solenoids. The devices and methods disclosed herein may also be applied to a variety of other solenoids. For non-limiting example, aspects of the present disclosure may be applied to normally vented (NV) “yellow cap” 6HP solenoids, “orange cap” 6HP solenoids, 8HP and 9HP ZF solenoids and various solenoids used in Ford 6R60 and 6R80 transmissions, among others. Further information on exemplary solenoids that may be remanufactured using the methods and devices disclosed herein are provided in “Technical Service Information, BMW ZF6HP21/28/34—Audi 6HP28, Preliminary Information,” (published by Automatic Transmission Services Group (ASTG), © 2013); “The ZF6HP26 Transmission, BMW Preliminary Information,” (Technical Services Information, 2007 Seminar Information published by ASTG) and “6R60 Transmission, Theory and Operation,” (© 2006, published by Ford Motor Company) each of which is incorporated by reference herein in its entirety.

#FIG. 1 shows hydraulic schematic 100 of hydraulic fluid paths in an exemplary ZF (TM) transmission having solenoids that may be remanufactured utilizing the techniques of the present disclosure. For example, aspects of the present disclosure may be used to remanufacture and reinstall any of solenoids EDS 1 through EDS 6, labeled collectively with reference numeral 102, also referred to herein as exemplary Original Equipment (OE) solenoid valves. The term “Original Equipment” and the abbreviation OE, and similar terms, as used herein, refer not only to solenoids and associated parts originally manufactured by a transmission manufacturer or originally sourced by a transmission manufacturer for inclusion in a transmission, but also refers to any aftermarket solenoids or solenoid parts conforming to the OE dimensions and specifications, for example, an aftermarket replacement solenoid for replacing a solenoid originally provided in a transmission. As shown in FIG. 1, in the illustrated ZF (TM) transmission, each of EDS solenoid valves 102 receive fluid from feed limit valve (Sol. Fd. Limit V) 103 and route fluid to their respective downstream valves. For example, EDS 1 routes fluid to Clutch Valve A (CV-A) and Holding Valve A (HV-A). As described more below, during use, the valve components of one or more of EDS solenoid valves 102 may begin to wear, causing leakage and causing an incorrect amount of fluid to be delivered to downstream components, which can lead to transmission malfunction.