FIELD

[0001] The present disclosure relates to a solenoid body with an integrated lead frame and a method of manufacturing a solenoid body with a lead frame.

BACKGROUND

[0002] This section provides background information related to the present disclosure which is not necessarily prior art.

[0003] Vehicle transmissions often include a solenoid module assembly mounted to a housing of the transmission. The solenoid module assembly typically includes a plurality of solenoids received in a solenoid body and configured to control the flow of fluid between different channels (e.g., fluid pathways) formed in the solenoid body. The solenoid body is mounted to the transmission housing such that these channels are in fluid communication with fluid channels formed in the transmission housing. The channels of the transmission housing can be in fluid communication with different devices within the transmission (e.g., clutches, torque converters, gear shift actuators) and/or can provide cooling to the transmission or various components. Typically the solenoid module assembly includes a lead frame that is separate from the solenoid body and is mounted to the solenoid body with fasteners. The lead frame typically includes a plurality of electrical leads that travel from one or more electrical connectors to the individual solenoids to provide electrical signals to the solenoids for controlling operation of the solenoids. The requirement of such fasteners to connect the separate components of the lead frame and the solenoid body can result in increased cost and increased size and weight of the solenoid module assembly.

SUMMARY

[0004] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. [0005] In one form, the present disclosure provides for a solenoid module assembly including an electrical connector, a plurality of electrically conductive leads, a solenoid body, a first solenoid valve, and a second solenoid valve. Each of the electrically conductive leads can have a first end coupled to the electrical connector for electrical communication therewith. Each electrically conductive lead can have an intermediate portion extending from the first end to a second end. The solenoid body can be a single, unitary, monolithic, solenoid body. The intermediate portion of each electrically conductive lead can extend within and be entirely surrounded by the solenoid body. The solenoid body can include a first solenoid valve bore, a second solenoid valve bore, a first supply cavity, a second supply cavity, a first control cavity, and a second control cavity. The first supply cavity can be open to an exterior of the solenoid body and the first solenoid valve bore. The second supply cavity can be open to an exterior of the solenoid body and the second solenoid valve bore. The first control cavity can be open to an exterior of the solenoid body and the first solenoid valve bore. The second control cavity can be open to an exterior of the solenoid body and the second solenoid valve bore. The first solenoid valve can be disposed within the first solenoid valve bore. The first solenoid valve can include a first supply port, a first control port, a first vent port, and a pair of first solenoid connectors. The first supply port can be in fluid communication with the first supply cavity. The first control port can be in fluid communication with the first control cavity. The first vent port can be in fluid communication with an exterior of the solenoid body. Each first solenoid connector can be coupled to the second end of a corresponding one of the electrically conductive leads for electrical communication therewith. The first solenoid valve can be configured to selectively control fluid communication between the first supply cavity, the first control cavity, and the first vent port. The second solenoid valve can be disposed within the second solenoid valve bore. The second solenoid valve can include a second supply port, a second control port, a second vent port, and a pair of second solenoid connectors. The second supply port can be in fluid communication with the second supply cavity. The second control port can be in fluid communication with the second control cavity. The second vent port can be in fluid communication with an exterior of the solenoid body. Each second solenoid connector can be coupled to the second end of a corresponding one of the electrically conductive leads for electrical communication therewith. The second solenoid valve can be configured to selectively control fluid communication between the second supply cavity, the second control cavity, and the second vent port.

[0006] In another form, the present disclosure provides for a solenoid module assembly for a transmission. The transmission can include a transmission housing and a transmission cover that cooperate to define a transmission cavity. The transmission housing can include a first supply conduit, a second supply conduit, a first control conduit, and a second control conduit. The solenoid module assembly can include an electrical connector, a plurality of electrically conductive leads, a solenoid body, a first solenoid valve, and a second solenoid valve. Each of the electrically conductive leads can have a first end coupled to the electrical connector for electrical communication therewith. Each electrically conductive lead can have an intermediate portion extending from the first end to a second end. The solenoid body can be a single, unitary, monolithic, structure disposed within the transmission cavity and mounted to a first side transmission housing. The intermediate portion of each electrically conductive lead can extend within and be entirely surrounded by the solenoid body. The solenoid body can have a second side opposing the first side of the transmission housing. The solenoid body can include a first solenoid valve bore, a second solenoid valve bore, a first supply cavity, a second supply cavity, a first control cavity, and a second control cavity. The first supply cavity can be open to the first solenoid valve bore and the second side to fluidly couple the first solenoid valve bore to the first supply conduit. The second supply cavity can be open to the second solenoid valve bore and the second side to fluidly couple the second solenoid valve bore to the second supply conduit. The first control cavity can be open to the first solenoid valve bore and the second side to fluidly couple the first solenoid valve bore to the first control conduit. The second control cavity can be open to the second solenoid valve bore and the second side to fluidly couple the second solenoid valve bore to the second control conduit. The first solenoid valve can be disposed within the first solenoid valve bore. The first solenoid valve can include a first supply port, a first control port, a first vent port, and a pair of first solenoid connectors. The first supply port can be in fluid communication with the first supply cavity. The first control port can be in fluid communication with the first control cavity. The first vent port can be in fluid communication with an exterior of the solenoid body. Each first solenoid connector can be coupled to the second end of a corresponding one of the electrically conductive leads for electrical communication therewith. The first solenoid valve can be configured to selectively control fluid communication between the first supply cavity, the first control cavity, and the first vent port. The second solenoid valve can be disposed within the second solenoid valve bore. The second solenoid valve can include a second supply port, a second control port, a second vent port, and a pair of second solenoid connectors. The second supply port can be in fluid communication with the second supply cavity. The second control port can be in fluid communication with the second control cavity. The second vent port can be in fluid communication with an exterior of the solenoid body. Each second solenoid connector can be coupled to the second end of a corresponding one of the electrically conductive leads for electrical communication therewith. The second solenoid valve can be configured to selectively control fluid communication between the second supply cavity, the second control cavity, and the second vent port.

[0007] In another form, the present disclosure provides for a method of manufacturing a solenoid module assembly. The method can include the step of forming a plurality of electrical leads from an electrically conductive material. Each of the electrical leads can have a first end, a second end, and an intermediate portion extending from the first end to the second end. The method can include the step of overmolding the electrical leads with a polymer material to form a single, unitary, monolithic, solenoid body. The intermediate portion of each electrical lead can extend within and be entirely surrounded by the solenoid body. The solenoid body can include a first solenoid valve bore, a second solenoid valve bore, a first supply cavity, a second supply cavity, a first control cavity, and a second control cavity. The first supply cavity can be open to an exterior of the solenoid body and the first solenoid valve bore. The second supply cavity can be open to an exterior of the solenoid body and the second solenoid valve bore. The first control cavity can be open to an exterior of the solenoid body and the first solenoid valve bore. The second control cavity can be open to an exterior of the solenoid body and the second solenoid valve bore.

[0008] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0009] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0010] Fig. 1 is a schematic partial section view of a transmission assembly, illustrating a solenoid module assembly mounted to a transmission housing;

[0011] Fig. 2 is a bottom perspective view of the solenoid module assembly of Fig. 1 , schematically illustrating a plurality of electrical leads within a solenoid body;

[0012] Fig. 3 is a top perspective view of the solenoid module assembly of Fig. 1 , illustrating the solenoid body and a filter plate;

[0013] Fig. 4 is a top view of the solenoid body of Fig. 3;

[0014] Fig 5. is a bottom perspective view of the filter plate of Fig. 3;

[0015] Fig. 6 is a top view of a set of electrical leads similar to those of Fig. 2; and

[0016] Fig. 7 is a schematic side view of the set of electrical leads of Fig. 6, illustrated within a mold apparatus during an overmolding process.

[0017] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0018] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0019] With reference to Figure 1 , a transmission assembly 10 for a vehicle

(not specifically shown) can include a transmission housing 14, a transmission cover 18, and a solenoid module assembly 22. The transmission assembly 10 can also include a plurality of fluid operated devices 26, such as hydraulically actuated clutches, torque converters, and/or gear shift actuators for example. The transmission housing 14 can have a bottom surface 30. The transmission housing 14 can include a plurality of fluid supply conduits 34 and fluid control conduits 38. The fluid supply conduits 34 can extend through the transmission housing 14 to a pump 42 that can be in fluid communication with a fluid reservoir 46 to pump fluid (e.g., hydraulic fluid) through the fluid supply conduits 34. The fluid supply conduits 34 can be open at the bottom surface 30. The fluid control conduits 38 can extend through the transmission housing 14 to the fluid operated devices 26 and can be open at the bottom surface 30. Alternatively, one or more of the fluid control conduits can be coupled to provide lubricating and/or cooling fluid to various components (e.g., gears) within the transmission assembly 10, while one or more of the fluid supply conduits 34 can be coupled to a lubricating and/or cooling circuit for delivering the lubricating and/or cooling fluid. While not specifically shown, return conduits can provide a fluid pathway for the fluid to return from the fluid operated devices 26 to the reservoir 46.

[0020] The solenoid module assembly 22 can include a solenoid body 50, an electrical connector 54, a plurality of electrically conductive leads 58, and a plurality of solenoid valves 62, 64, 66. In the example provided, the solenoid module assembly 22 can also include a filter panel 70, and one or more sensors 74, 76. The solenoid body 50 can be a single, unitary, monolithic structure, as described in greater detail below. In the example provided, the solenoid body 50 is a molded polymer material. The solenoid body 50 can be mounted to the transmission housing 14 such that a top side 78 of the solenoid body 50 opposes the bottom surface 30 of the transmission housing 14 and covers the openings of the fluid supply conduits 34 and the fluid control conduits 38. The solenoid body 50 can be in sealing contact with the bottom surface 30 of the transmission housing 14, such that fluid can flow from the fluid supply conduits 34 and fluid control conduits 38 into the solenoid body 50, as described in greater detail below. In the example provided, the filter panel 70 forms the seal between the solenoid body 50 and the transmission housing 14, as described in greater detail below. [0021] In general, the solenoid valves 62, 64, 66 can be at least partially disposed within the solenoid body 50 and configured to control flow of fluid through the solenoid body 50, as described in greater detail below. The electrical connector 54 can be fixedly coupled to a bottom side 82 of the solenoid body 50 that is opposite the top side 78. The electrical connector 54 can be unitarily formed with the solenoid body 50 or can be attached thereto. The electrical connector 54 can be configured to mate with a mating electrical connector 86 which can then transmit electrical signals to/from the solenoid module assembly 22 (e.g., to/from an electrical control module of the vehicle).

[0022] The transmission cover 18 can be mounted to the transmission housing 14 and can enclose the solenoid module assembly 22 within a cavity 90 defined by the transmission housing 14 and the transmission cover 18. The electrical connector 54 can be a bulk-head type connector and can extend through an aperture 94 formed in the transmission cover 18 such that the mating electrical connector 86 can mate with the electrical connector 54 externally of the transmission cover 18. The electrical connector 54 can have a seal 98 that seals with the transmission cover 18 to inhibit fluid and/or particulates from entering or exiting the cavity 90 through the aperture 94.

[0023] With additional reference to Figures 2-4, the solenoid body 50 can include a plurality of mounting bores 210, a first solenoid valve bore 214, a second solenoid valve bore 218, a first supply cavity 222, a second supply cavity 226, a first control cavity 230, a second control cavity 234, a first vent cavity 238, a second vent cavity 242, a pair of first lead apertures 246, and a pair of second lead apertures 250. In the example provided, the solenoid body 50 can include a third solenoid valve bore 254, a third supply cavity 258, a third control cavity 262, a third vent cavity 266, a pair of third lead apertures 270, a first sensor bore 274, and a second sensor bore 276. In alternative constructions, not specifically shown, the solenoid body 50 can include additional solenoid valve bores, similar to the solenoid valve bores 214, 218, 254, and/or additional sensor bores similar to sensor bores 274, 276.

[0024] The mounting bores 210 can extend through the top side 78 and the bottom side 82 of the solenoid body 50. In the example provided, each mounting bore 210 can be lined with a metal, hollow, cylindrical tube open at the top and bottom sides 78, 82 of the solenoid body 50. The tubes can be fixedly positioned in the mounting bores 210, such as by press-fit or by the solenoid body 50 being overmolded thereon for example. A fastener (e.g., bolt, not specifically shown) can be received through each mounting bore and can be fastened (e.g., via mating threads) to the transmission housing 14 (Figure 1 ) to mount the solenoid body 50 to the transmission housing 14 (Figure 1 ).

[0025] The first solenoid valve bore 214 can be open at a first side 282 of the solenoid body 50 and can extend into the solenoid body 50 to be in fluid communication with the first supply cavity 222, the first control cavity 230, and the first vent cavity 238. The second solenoid valve bore 218 can be open at the first side 282 of the solenoid body 50 and can extend into the solenoid body 50 to be in fluid communication with the second supply cavity 226, the second control cavity 234, and the second vent cavity 242. The third solenoid valve bore 254 can be open at the first side 282 of the solenoid body 50 and can extend into the solenoid body 50 to be in fluid communication with the third supply cavity 258, the third control cavity 262, and the third vent cavity 266.

[0026] The first, second, and third supply cavities 222, 226, 258 can be open to the top side 78 of the solenoid body 50. The supply cavities 222, 226, 258 can have shapes that can correspond with and align with the openings (e.g., worm-trails) of the fluid supply conduits 34 at the bottom surface 30 of the transmission housing 14, such that the supply cavities 222, 226, 258 can be in fluid communication with a corresponding one of the fluid supply conduits 34.

[0027] The first, second, and third control cavities 230, 234, 262 can be open to the top side 78 of the solenoid body 50. The control cavities 230, 234, 262 can have shapes that can correspond with and align with the openings (e.g., worm-trails) of the control conduits 38 at the bottom surface 30 of the transmission housing 14, such that the control cavities 230, 234, 262 can be in fluid communication with a corresponding one of the control conduits 38.

[0028] The first, second, and third vent cavities 238, 242, 266 can be open to the top side 78 of the solenoid body 50. The vent cavities 238, 242, 266 can be positioned to correspond with and align with openings in the bottom surface 30 of the transmission housing 14, such that the vent cavities 238, 242, 266 can be in fluid communication with an interior of the transmission housing 14 and such that fluid vented into the transmission housing 14 through the vent cavities 238, 242, 266 can be returned to the reservoir 46.

[0029] The first lead apertures 246 can be open at the first side 282 of the solenoid body 50 and can be proximate to the first solenoid valve bore 214. The second lead apertures 250 can be open at the first side 282 of the solenoid body 50 and can be proximate to the second solenoid valve bore 218. The third lead apertures 270 can be open at the first side 282 of the solenoid body 50 and can be proximate to the third solenoid valve bore 254.

[0030] The electrically conductive leads 58 can be disposed within the solenoid body 50. Each lead 58 can have a first end that is connected to the electrical connector 54, a second end that is disposed within a corresponding one of the lead apertures 246, 250, 270 or a corresponding one of the sensor bores 274, 276, and an intermediate portion that extends between the first and second ends. Each first end can be connected to a corresponding pin (e.g., pin 310) within the electrical connector for electrical communication therewith. The intermediate portions can be entirely within and surrounded by the solenoid body 50. In the example provided, the solenoid body 50 is overmolded on the conductive leads 58.

[0031] The first, second, and third solenoid valves 62, 64, 66 can each have a respective first, second or third supply port 314, 316, 318, control port 322, 324, 326, and vent port 330, 332, 334, that can be separated by seals 338 (e.g., O-rings). The solenoid valves 62, 64, 66 can be any suitable type of solenoid valve configured to selectively control flow of fluid within the solenoid valve 62, 64, 66 between the supply port 314, 316, 318, the control port 322, 324, 326, and the vent port 330, 332, 334 by receiving electrical signals from a pair of solenoid connectors 342. For example, each solenoid valve 62, 64, 66 can have an electromagnet that drives an armature to move a valve element within the solenoid valve 62, 64, 66 to selectively permit or inhibit fluid communication between the supply port 314, 316, 318, the control port 322, 324, 326, and the vent port 330, 332, 334 depending on the axial position of the armature.

[0032] The first solenoid valve 62 can be received in the first solenoid valve bore 214, such that the solenoid connectors 342 of the first solenoid valve 62 are received in the first lead apertures 246 and contact the second ends of the corresponding electrical leads 58 to be in electrical communication therewith. The first supply port 314 can be in communication with the first supply cavity 222. The first control port 322 can be in communication with the first control cavity 230. The first vent port 330 can be in communication with the first vent cavity 238. In an alternative construction, not specifically shown, the solenoid body 50 can be without the first vent cavity 238 and the first vent port 330 can be in direct fluid communication with an exterior of the solenoid body 50.

[0033] The second solenoid valve 64 can be received in the second solenoid valve bore 218, such that the solenoid connectors 342 of the second solenoid valve 64 are received in the second lead apertures 250 and contact the second ends of the corresponding electrical leads 58 to be in electrical communication therewith. The second supply port 316 can be in communication with the second supply cavity 226. The second control port 324 can be in communication with the second control cavity 234. The second vent port 332 can be in in communication with the second vent cavity 242. In an alternative construction, not specifically shown, the solenoid body 50 can be without the second vent cavity 242 and the second vent port 332 can be in direct fluid communication with an exterior of the solenoid body 50.

[0034] The third solenoid valve 66 can be received in the third solenoid valve bore 254, such that the solenoid connectors 342 of the third solenoid valve 66 are received in the third lead apertures 270 and contact the second ends of the corresponding electrical leads 58 to be in electrical communication therewith. The third supply port 318 can be in communication with the third supply cavity 258. The third control port 326 can be in communication with the third control cavity 262. The third vent port 334 can be in communication with the third vent cavity 266. In an alternative construction, not specifically shown, the solenoid body 50 can be without the third vent cavity 266 and the third vent port 334 can be in direct fluid communication with an exterior of the solenoid body 50.

[0035] The first sensor bore 274 can be formed in the top side 78 of the solenoid body 50 and can extend into the solenoid body 50. The first sensor bore 274 can be in fluid communication with one of the cavities 222, 226, 230, 234, 238, 242, 258, 262, 266. In the example provided, the first sensor bore 274 is in fluid communication with the first supply cavity 222. In an alternative configuration, not specifically shown, the first sensor bore 274 can be in fluid communication with a different one of the cavities 226, 230, 234, 238, 242, 258, 262, 266. The first sensor 74 (e.g., a pressure sensor) can be received in the first sensor bore 274 and can be configured to output an electrical signal indicative of a pressure within the cavity (e.g., within the first supply cavity 222). The first sensor 74 can contact the second ends of the corresponding leads 58 to be in electrical communication therewith.

[0036] The second sensor bore 276 can be formed in the top side 78 of the solenoid body 50 and can extend into the solenoid body 50. The second sensor bore 276 can be in fluid communication with one of the cavities 222, 226, 230, 234, 238, 242, 258, 262, 266. In the example provided, the second sensor bore 276 is in fluid communication with the second supply cavity 226. In an alternative configuration, not specifically shown, the second sensor bore 276 is in fluid communication with a different one of the cavities 222, 230, 234, 238, 242, 258, 262, 266. The second sensor 76 (e.g., a pressure sensor) can be received in the second sensor bore 276 and can be configured to output an electrical signal indicative of a pressure within the cavity (e.g., within the second supply cavity 226). The second sensor 76 can contact the second ends of the corresponding leads 58 to be in electrical communication therewith.

[0037] The filter panel 70 can include a filter panel body 410, one or more filter elements 414, one or more top seals 418 (Figure 3), and one or more bottom seals 422 (Figure 5). The filter panel body 410 can include a plurality of mounting bores 426, which can extend through the filter panel body 410 and through a top side 430 and a bottom side 434 of the filter panel body 410. The mounting bores 426 of the filter panel body 410 can correspond to and align with the mounting bores 210 of the solenoid body 50. The filter panel body 410 can include a first supply aperture 438, a first control aperture 442, a first vent aperture 446, a second supply aperture 450, a second control aperture 454, and a second vent aperture 458 that can extend through the filter panel body 410 and through the top and bottom sides 430, 434 of the filter panel body 410. In the example provided, the filter panel body 410 can also include a third supply aperture 462, a third control aperture 466, and a third vent aperture 470 that can extend through the filter panel body 410 and through the top and bottom sides 430, 434 of the filter panel body 410.

[0038] The first supply aperture 438 can have a shape that corresponds with and aligns with the opening of the first supply cavity 222 at the top side 78 of the solenoid body 50. The first control aperture 442 can have a shape that corresponds with and aligns with the opening of the first control cavity 230 at the top side 78 of the solenoid body 50. The first vent aperture 446 can have a shape that corresponds with and aligns with the opening of the first vent cavity 238 at the top side 78 of the solenoid body 50.

[0039] The second supply aperture 450 can have a shape that corresponds with and aligns with the opening of the second supply cavity 226 at the top side 78 of the solenoid body 50. The second control aperture 454 can have a shape that corresponds with and aligns with the opening of the second control cavity 234 at the top side 78 of the solenoid body 50. The second vent aperture 458 can have a shape that corresponds with and aligns with the opening of the second vent cavity 242 at the top side 78 of the solenoid body 50.

[0040] The third supply aperture 462 can have a shape that corresponds with and aligns with the opening of the third supply cavity 258 at the top side 78 of the solenoid body 50. The third control aperture 466 can have a shape that corresponds with and aligns with the opening of the third control cavity 262 at the top side 78 of the solenoid body 50. The third vent aperture 470 can have a shape that corresponds with and aligns with the opening of the third vent cavity 266 at the top side 78 of the solenoid body 50.

[0041] The one or more filter elements 414 can span across one or more of the apertures 438, 442, 446, 450, 454, 458, 462, 466, 470. The filter element 414 can be any suitable type of filter medium, such as a mesh screen (e.g., metal or plastic screen) configured to permit fluid to pass through, while inhibiting particulates greater than a predetermined size from passing through the corresponding aperture 438, 442, 446, 450, 454, 458, 462, 466, 470. In the example provided, the filter element 414 is a single, flat screen that is overmolded by the filter panel body 410 and covers all of the apertures 438, 442, 446, 450, 454, 458, 462, 466, 470. Alternatively, individual filter elements can be used, or some of the apertures 438, 442, 446, 450, 454, 458, 462, 466, 470 can be not covered by the filter element 414.

[0042] The one or more top seals 418 can extend along the top side 430 of the filter panel body 410 and between the various apertures 438, 442, 446, 450, 454, 458, 462, 466, 470. The top seals 418 can form a seal between the top side 430 of the filter panel body 410 and the bottom surface 30 of the transmission housing 14. In the example provided, the filter panel 70 includes compressible (e.g., rubber) gaskets or seal beads that form the top seals 418 and are received in corresponding grooves formed in the top side 430 of the filter panel body 410. The first gasket can extend about and between the first supply aperture 438, the first control aperture 442, and the first vent aperture 446. The second gasket can extend about and between the second supply aperture 450, the second control aperture 454, and the second vent aperture 458. Alternatively, a single gasket can be used that extends about and between the apertures 438, 442, 446, 450, 454, 458, 462, 466, 470.

[0043] The one or more bottom seals 422 can extend along the bottom side 434 of the filter panel body 410 and between the various apertures 438, 442, 446, 450, 454, 458, 462, 466, 470. The bottom seals 422 can form a seal between the bottom side 434 of the filter panel body 410 and the top side 78 of the solenoid body 50. In the example provided, the filter panel 70 includes compressible (e.g., rubber) gaskets or seal beads that form the bottom seals 422 and are received in corresponding grooves formed in the bottom side 434 of the filter panel body 410. The first gasket can extend about and between the first supply aperture 438, the first control aperture 442, and the first vent aperture 446. The second gasket can extend about and between the second supply aperture 450, the second control aperture 454, and the second vent aperture 458. Alternatively, a single gasket can be used that extends about and between the apertures 438, 442, 446, 450, 454, 458, 462, 466, 470. In the example provided, the top and bottom seals 418, 422 can be formed in a single step by molding rubber into the corresponding grooves formed in the top and bottom sides 430, 434 of the filter panel body 410 simultaneously, though other methods can be used.

[0044] With additional reference to Figure 6, a top view of a set of electrical leads 610 is illustrated. The set of electrical leads 610 can be similar to the electrical leads 58 described above with reference to Figures 1 -5 and can include individual electrical leads that can have first ends (e.g., first end 614), second ends (e.g., second end 618), and intermediate portions (e.g., intermediate portion 622) that can extend between the first and second ends. Similar to the electrical leads 58, the first ends of the electrical leads 610 of Figure 6 can be connected to pins (e.g., pin 626, similar to pin 310 of Figures 1 -4), or can be formed into pins, while the second ends can be configured to connect to a corresponding sensor or solenoid valve. The set of electrical leads 610 can be formed of an electrically conductive material (e.g., copper) and can be stamped into a desired shape and path.

[0045] With additional reference to Figure 7, a side view of an injection mold 710 is schematically illustrated. The injection mold 710 can include a set of dies 714, which can have an internal structure corresponding to the shape of the solenoid body (e.g., solenoid body 50). The injection mold 710 can include a material inlet 718 and a vent 722 and can include one or more chaplet pins 726. The set of electrical leads 610 can be positioned within the dies 714 and can be supported therein by the chaplet pins 726. The inlet 718 can be configured to permit liquid material (e.g., polymer) to be injected into the interior of the dies 714. The material can be injected under heat and pressure. The vent 722 can permit air to be pushed out from the interior of the dies 714 such that the interior can be filled with the material. As the interior of the dies fills with liquid material, the material can completely surround the set of electrical leads 610 at least at the intermediate portions 622 (Figure 6), such that the electrical leads 610 are overmolded by the material. The liquid material can be allowed to solidify to form the solenoid body 50 (Figures 1 -4), such that the solenoid body 50 (Figures 1 -4) is overmolded on the electrical leads.

[0046] Once the material has solidified, the solenoid body (with the electrical leads 610) can be removed from the dies 714 for further processing or assembly with the solenoid valves 62, 64, 66 (Figures 1 , 2, and 4). The solenoid valve bores 214, 218, 254 (Figures 1 -4), mounting bores 210, lead apertures 246, 250, 270, sensor bores 274, 276, and cavities 222, 226, 230, 234, 238, 242, 258, 262, 266 (Figure 4) can be formed during the molding process due to the interior structure of the dies 714. Alternatively, the solenoid valve bores 214, 218, 254 (Figures 1 -4), mounting bores 210, lead apertures 246, 250, 270, sensor bores 274, 276, and/or cavities 222, 226, 230, 234, 238, 242, 258, 262, 266 (Figure 4) can be formed during additional processing after the overmolding process.

[0047] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.

[0048] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0049] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0050] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0051] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

[0052] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0053] Spatially relative terms, such as "top," "bottom," "left," "right," "front," "back", "forward," "behind," "beneath," "below," "lower," "above," "over," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0054] None of the elements recited in the claims are intended to be a means-plus-function element within the meaning of 35 U.S.C. §1 12(f) unless an element is expressly recited using the phrase "means for," or in the case of a method claim using the phrases "operation for" or "step for."