WINDING”

FIELD OF THE INVENTION

The present invention relates to a solenoid valve. More particularly, the present invention relates to an improved solenoid valve for purge control or the EVAP system solenoid valve like FTIV, Canister Vent Valve with a winding of aluminum wire for cost effectiveness and reduced weight.

BACKGROUND OF THE INVENTION

A solenoid valve is an electrically controlled valve used in variety of applications such as fuel tank valve, purge valves, air bypass valves, vapor blocking valves, refueling vent valve, canister vent valve, water (like Electric water pump etc.), pneumatic (like vacuum solenoid valve, Turbocharger solenoid valve, Electronic Vacuum Regulator Valve etc.) & other solenoid valves. The solenoid valve finds its utility wherever a fluid flow must be controlled/ maintained.

Solenoid valves when electrically energized or de-energized, either shut off or allow flow. The actuation takes the form of an electromagnet and when energized, a magnetic field builds up which pulls a plunger or pivoted armature against the action of a spring. When de-energized, the plunger or pivoted armature is returned to its original position by the spring action. Based on application, the solenoid valves are either two port or three port valves.

A solenoid valve used for purge control, generally called as purge valve or purge control solenoid valve is a part of vehicle’s evaporative emission control (EVAP) system. The EVAP system is responsible plays an important role in preventing fuel vapors in the fuel tank from escaping into the atmosphere. The EVAP system traps fuel vapors from the fuel tank and temporarily stores them in a charcoal canister. The purge valve is precisely controls the amount of fuel vapor that is purged from the charcoal canister to engine.

In a solenoid valve, the solenoid subassembly comprises of a bobbin with a coil winding having a magnetic return path. The bobbin is usually made of an electrically insulated material while the coil winding should have an electrical conductivity. Copper having a very high electrical conductivity is the most suitable material for coil winding. But copper on the other hand is an expensive and heavy metal because of high density as compared to AT and hence it increases the cost as well as weight of the solenoid valve. Also on the other hand Aluminum is also a good thermal and electrical conductor.

CA2857301A1 relates to a solenoid pilot valve for a hydraulic valve, for household appliances. This valve comprises at least one core mounted movably within a portion of said body and inside said chamber and carrying a closing member cooperating with the valve seat; and an actuator including a solenoid or coil of copper wire, mounted around said portion of the body. Copper being a costly and heavy metal increases the overall cost and weight of the product.

Therefore, there is a need of an alternate material which makes the solenoid valve cost effective and significantly reduces the weight of the solenoid valve as well as overall weight of the product to which it is employed.

OBJECT OF THE INVENTION

The main object of the present invention is to provide an improved solenoid valve with a winding of aluminum wire which is useful in variety of application such as Fuel Tank Valve, Purge Valves, Air Bypass valves, Vapor blocking/Refueling vent valve/Canister Vent Valve, water solenoid valve (like Electric water pump etc.), pneumatic (like vacuum solenoid valve, Turbocharger solenoid valve, Electronic Vacuum Regulator Valve etc.) & other solenoid valves used in the application of EVAP & Engine of 2 wheelers & 4 wheelers application.

Another object of the present invention is to provide an improved solenoid valve with a winding of aluminum wire that reduces the cost as well as the weight of the product significantly.

Yet another object of the present invention is to provide an improved solenoid valve with a winding of aluminum wire that is joined with the terminals preferably made of brass or brass alloy material through a joining process including but not limited to soldering or crimping. Still another object of the present invention is to provide an improved solenoid valve for purge control which is cost effective and light weight due to use of winding of aluminum wire.

SUMMARY OF THE INVENTION

The present invention relates to an improved solenoid valve which is cost effective and has a reduced weight due to utilization of aluminum wire for coil winding.

In a preferred embodiment, the present invention provides an improved solenoid valve for purge control comprising of a housing, at least one bobbin assembly with integrated nozzles, at least one slotted bracket, a moving core, a spring, an U-bracket, a fixcore, a coil winding, a plurality of terminals and at least one O-ring optionally provided for better sealing. The coil winding of aluminum wire is wound on the outer diameter of the bobbin assembly forming a solenoid. When the coil winding is energized, a magnetic field is set up and the moving core moves towards the fixcore opening an air flow passage. The fixcore is a magnetic core fixed to the inner diameter of the bobbin assembly and gets magnetized when solenoid is energized. The O-ring to control body leakage during energized condition. While in de-energized condition, the moving core seals the bobbin. The spring helps in resetting the position of moving core on de energization. The housing encloses the coil sub assembly comprising the bobbin part of the bobbin assembly and coil winding and terminals. The slotted bracket and U bracket provides magnetic path after crimped together. The aluminum wire used for coil winding makes the solenoid valve cost effective and light weighted. Further, the terminals are preferably made of brass or brass alloy material and joined with aluminum wire through a joining process including but not limited to soldering or crimping.

In an embodiment, the present invention provides an improved solenoid valve comprising of a valve body, at least one plunger, at least one fixcore, at least one bobbin assembly with inlet & outlet port, a coil winding, at least one spring and a plurality of terminals for electrical connection. The material for coil winding is ideally an electrically conductive material and the bobbin part is made of an electrically insulated material. Copper due to very high electrical conductivity is the most preferred material, however increases the overall weight and cost of the product. Hence, the material for coil winding as per present invention is aluminum wire that is cost effective and has reduced weight. Further, the terminals are preferably made of brass or brass alloy material and joined with aluminum wire through a joining process including but not limited to soldering or crimping. Therefore the present invention provides an approach to make the solenoid valve cost effective and light weighted and is useful is applications such as Purge Control Valve, Isolation Valve, Air Bypass Valves, Vapor Blocking Valve/Refueling Vent Valve/Canister Vent Valve, water Solenoid Valve (like Electric water pump etc.) , pneumatic (like vacuum solenoid valve, Turbocharger solenoid valve, Electronic Vacuum Regulator Valve etc.) & other solenoid valves used in the application of EVAP & Engine of 2-Wheeler & 4-Wheeler application.

BRIEF DESCRIPTION OF THE DRAWINGS

An understanding of the device of the present invention may be obtained by reference to the following drawings:

Fig. 1 shows a section diagram of the improved purge valve for purge control in accordance with the present invention.

Fig. 2 shows a bar diagram for comparison of copper and aluminum on basis of price.

Fig. 3 shows a bar diagram for comparison of copper and aluminum on basis of weight. Fig. 4 shows a bar diagram for comparison of copper and aluminum on basis of electrical and pneumatic functional performance.

DETAILED DESCRIPTION OF THE INVENTION

Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

The present invention provides an improved solenoid valve with a winding of aluminum wire which is useful in variety of application such as Fuel Tank Valve, Purge Valves, Air Bypass valves, Vapor blocking valve/ Refueling vent valve/Canister Vent Valve.

In a preferred embodiment, the present invention provides an improved solenoid valve for purge control comprising of a housing, at least one bobbin, at least one slotted bracket, a moving core, a spring, an U-bracket, a fixcore, a coil winding, a plurality of terminals and at least one O-ring (O-ring provide optionally to provide more sealing). The coil winding of aluminum wire is wound on the outer diameter of the bobbin part of bobbin assembly forming a solenoid. When the coil winding is energized, a magnetic field is set up and the moving core moves towards the fixcore opening an air flow passage. The fixcore is a magnetic core fixed to the inner diameter of the bobbin assembly and gets magnetized when solenoid is energized. The O-ring to control leakage during energized condition. While in de-energized condition, the moving core seals the bobbin. The spring helps in resetting the position of moving core on de -energization. The housing encloses the coil sub assembly comprising the bobbin part and coil winding and terminals. The slotted bracket and U bracket provide magnetic path after crimped together. The aluminum wire used for coil winding makes the solenoid valve cost effective and light weighted. Further, the terminals are preferably made of brass or brass alloy material and joined with aluminum wire through a joining process including but not limited to soldering or crimping.

In an embodiment, the present invention provides an improved solenoid valve comprising of a valve body, at least one plunger, at least one fixcore, at least one bobbin assembly with integrated atleast one inlet and one outlet port, a coil winding, at least one spring and a plurality of terminals for electrical connection. The material for coil winding is ideally an electrically conductive material and the bobbin assembly is made of an electrically insulated material. Here, the material for coil winding is aluminum wire that is cost effective and has reduced weight. When power is applied to solenoid valve through terminals, magnetic field develops with help of aluminum wire which eventually helps in movement of plunger and performing respective operation based on application in which it is implemented. Further, the terminals are preferably made of brass or brass alloy material and joined with aluminum wire through a joining process including but not limited to soldering or crimping.

Referring to Fig. 1, a sectional view of the improved solenoid valve for purge control is shown. The improved solenoid valve 10 for purge control has a bobbin assembly 1 and on its outer diameter coil winding 8 is wound which sets up magnetic field when energized. The housing 2 encloses the bobbin assembly 1 with integrated nozzles with coil winding 8 and this housing 2 is inserted in a U-bracket 6 and closed at the top with a slotted bracket 3. The moving core 4 is assembled over the fixcore 7. The moving core 4 seals the bobbin assembly 1 during de-energized condition and moves towards fixcore 7 during energized condition opening an air flow passage. A spring 5 resets the position of moving core 4 on de-energized condition. The coil winding is preferably made of aluminum wire which is light weighted and cost effective compared to conventional copper wire.

Fig. 2 shows a bar diagram for comparison of copper and aluminum on basis of price. The price of aluminum wire is approximately 40% less than copper wire. With use of aluminum wire for coil winding, the solenoid valve also becomes cost effective compared to solenoid valve with copper wire used as coil winding.

Fig. 3 shows a bar diagram for comparison of copper and aluminum on basis of weight. The aluminum wire has approximately 15% less weight than the weight of the copper wire. Due to more weight, the solenoid valves with copper wire as coil winding when employed in a vehicle or other product increases the overall weight of the product. Fig. 4 shows a bar diagram for comparison of copper and aluminum on basis of electrical and pneumatic functional performance. On the basis of electrical and pneumatic functional performance, the aluminum wire used as a coil winding is equally efficient as copper wire and suitable for use as coil winding in a solenoid valve. Therefore, the present invention provides an improved solenoid valve which is cost effective and has reduced weight as the conventionally used copper wire for coil winding is replaced with a light weight and comparatively much cheaper aluminum wire.

The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.