If, for any reason, the unitary coil and valve assembly requires maintenance, repair or disposal it may be quickly and inexpensively removed without determinating any wires or leads and without disconnecting any pipes, tubes or conduits from any of the ports in the body.

Background of the Invention United States Patent No. 5, 180, 318 to Moller et al. discloses connector modules which are interconnected longitudinally and include neutral, signal and grounded conductors. The signal conductor is installed using a screwdriver as is illustrated in Fig. 4 of the'318 patent.

United States Patent No. 5, 178, 548 to Fortmann et al. discloses contact pins which mate with receptacles. Rotor bodies having conductive and ductile properties serve as contact rings and electrical conductors.

United States Patent No. 5, 581, 222 to Pinaud discloses a rapid assembly solenoid valve having a groove which is secured by a wire spring clip to the housing of the valve. The wire spring clip is disclosed and claimed as being pivotally mounted to the housing.

United States Patent No. 4, 805, 870 to Mertz discloses a spring clip secured to the housing by means of spot welding or the like. United States Patent No. 5, 158, 475 to Tyler discloses a spring clip which resiliently grips the bare wire end of a conductor that is inserted into a connector.

United States Patent No. 4, 880, 033 to Neff discloses a poppet valve

wherein the spool valve includes an annular molded poppet valve member 50 which during assembly must be forced over its seating surfaces.

None of the related art discloses or suggests a solenoid valve having a unitary coil and valve assembly which is affixed to a body by means of a clip.

Nor does the related art suggest or disclose electrical power supplied to a coil by a first set of contacts which reside in the body in combination with a second set of contacts which are part of the unitary coil and valve assembly.

Summary of the Invention A solenoid valve comprising a unitary coil and valve assembly and a body is disclosed. The unitary coil and valve assembly include the first bobbin and a second bobbin. The second bobbin is ultrasonically welded to the first bobbin forming a bobbin assembly. A coil is wound around the second bobbin. A balanced spool having first and second positions is provided. The balanced spool includes an elongated stem portion which engages a plunger. The plunger also has first and second positions.

The balanced spool is partially overmolded with rubber. The partially overmolded portion of the balanced spool engages the bobbin assembly. A washer and a stop are also overmolded to the second bobbin.

The balanced spool includes a bore. A spring partially resides in the bore of the balanced spool and urges the balanced spool toward its second position. The first bobbin includes first and second exterior slots. The body includes first and second bores for receiving the clip. A clip extends from the exterior of the body and through a portion of the body and into the first and second slots of the first bobbin affixing the first and second bobbins (and, hence, the unitary coil and valve assembly) to the body.

The body includes a first port, a second port and a third port. The first and second ports reside in a first horizontal plane and the third port resides in a second horizontal plane. The second bobbin includes a first passageway

which communicates with the first port of the body. The first bobbin includes a second passageway which communicates with the second port of the body.

The first bobbin includes a third passageway which communicates with the third port of the body. The first and second ports of the body communicate when the balanced spool and the plunger are in their first respective positions.

The second and third ports of the body communicate when the balanced spool and the plunger are in their respective second positions. The first bobbin and the second bobbin comprise the bobbin assembly as the first and second bobbins are ultrasonically welded together. Therefore, the first passageway in the second bobbin, the second passageway in the first bobbin, and the third passageway in the first bobbin are sometimes described later herein as the first, second and third passageways of the bobbin assembly.

The body includes a first set of electrical contacts. The unitary coil and valve assembly includes a second set of electrical contacts. The first set of electrical contacts engage the second set of electrical contacts when the unitary coil and valve assembly is affixed to the body. The second set of electrical contacts are wired to the coil. The first set of electrical contacts are wired to a power source. A plate is ultrasonically welded to the second body.

An enclosure is ultrasonically welded to the plate and to the second bobbin.

Alternatively, instead of employing ultrasonic welding those skilled in the art may weld by other methods or may use adhesive.

It is an object of the invention to provide a unitary coil and valve assembly which can be quickly and easily removed from the body without having to determinate any electrical wires or pipeline connections.

It is a further object of the present invention to provide a unitary coil and valve assembly which is secured to the body by a clip.

It is a further object of the present invention to provide a unitary coil and valve assembly which is affixed to the body by a clip.

It is a further object of the present invention to provide a solenoid valve having a unitary coil and valve assembly, a first set of electrical contacts and a second set of electrical contacts.

It is a further object of the present invention to provide a solenoid valve comprising a unitary coil and valve assembly which includes a spool which moves in conjunction with a plunger. The spool is a balanced spool and includes an overmolded portion. The overmolded portion of the body engages various seating surfaces of the bobbin thus allowing flow through the bobbin and hence through the body in the desired fashion.

It is a further object of the present invention to provide a solenoid valve which includes a first and second bobbin which are ultrasonically welded together.

It is a further object of the present invention to provide a washer and a stop which are overmolded to a second bobbin.

It is a further object of the present invention to provide a solenoid valve which includes a bobbin which is ultrasonically welded to a plate.

It is a further object of the present invention to provide an enclosure which encloses the housing and second bobbin.

It is a further object of the present invention to provide a manual operator for moving the plunger and the spool from their second positions to their respective first positions.

It is a further object of the present invention to provide a solenoid valve which includes a unitary coil and valve assembly which controls the flow of gas or other fluid between any two of the three ports of the body.

It is a further object of the present invention to provide a bobbin assembly comprised of the first bobbin and the second bobbin.

The objects of the invention will be better understood when taken in conjunction with the brief description of the drawings and the detailed

description of the invention which follow below.

Brief Description of the Drawings Fig. 1 is a side view of the solenoid valve illustrating the body and the first port of the body as well as the unitary coil and valve assembly shown partially in cross-section.

Fig. 2 is a front view of the solenoid valve illustrating the body and the third port of the body as well as the unitary coil and valve assembly shown partially in cross-section.

Fig. 3 is a cross-sectional view of the solenoid valve taken along the lines 3-3 of Fig. 1 illustrating the body and the first and second ports of the body as well as the unitary coil and valve assembly. Fig. 3 also illustrates the unitary coil and valve assembly ultrasonically welded to a plate. Fig. 3 also illustrates an ultrasonically welded two-piece bobbin, an overmolded spool, a plunger, a coil and a spring. Fig. 3 illustrates the spool and the plunger in their second positions. When the spool and the plunger are in their second positions the second port in the body communicates with the third port in the body. Fig. 3 illustrates the condition that exists when the coil is deenergized.

Fig. 3A is an enlarged view of a portion of Fig. 3 illustrating the spool and the bobbins. The spool is in its second position in Fig. 3A as shown.

Fig. 4 is a cross-sectional view of the solenoid valve similar to the view illustrated in Fig. 3 except the plunger and spool are illustrated in their respective first positions. Fig. 4 illustrates the first port in the body communicating with the second port in the body. Fig. 4 illustrates the condition that exists when the coil is energized.

Fig. 4A is an enlarged view of a portion of Fig. 4 illustrating the spool and the bobbins. The spool is in its first position in Fig. 4A as shown.

Fig. 5 is a cross-sectional view of the unitary coil and valve assembly taken along the lines 3-3 of Fig. 1.

Fig. 6 is a cross-sectional front view of the body.

Fig. 7 is a sectional view taken along the lines 7-7 of Fig. 2 illustrating the first port as well as one of the electrical contacts of the unitary coil and valve assembly and one of the electrical contacts of the body.

Fig. 8 is a view taken along the lines 8-8 of Fig. 2 illustrating the body and second port in cross-section as well as one of the electrical contacts of the unitary coil and valve assembly (illustrated in a fragmentary cross-section view) and one of the electrical contacts of the body.

Fig. 9 is a cross-sectional view taken along the lines 9-9 of Fig. 2 illustrating the third port with the plunger and the spool in their respective second positions.

Fig. 10 is an isometric view of a portion of the unitary coil and valve assembly.

Fig. 11 is a diagram of process steps in assembling the unitary coil and valve assembly.

Detailed Description of the Invention Fig. 1 is a side view of the solenoid valve illustrating the body 1 and the first port 17 of the body as well as the unitary coil and valve assembly shown partially in cross-section. The unitary coil and valve assembly is best illustrated in Fig. 5. Fig. 1 further illustrates the first passageway 28 in the first port 17 of the body 1. Clip 6 is partially shown exterior to the body 1.

Clip 6 is a spring loaded clip which grips the slots 41 and 41'of the first bobbin 3. See, Fig. 5 which illustrates the slots 41 and 41'. The spring loading of the clip 6 keeps the clip in engagement with the slots 41 and 41'and the first and second bores 46,47 in the body 1. See, Fig 6. Alternatively, or in addition, clip 6 may have serration 70 to insure that it stays in place securing the bobbin assembly (comprising the first bobbin 3 and second bobbin 4) in place with respect to the body. The strap 13 which houses the electrical coil is

shown in Fig. 1 as well.

An electrical lead wire 37 is illustrated leading from the first electrical contact 31 to the coil 5 which is inside strap 13. Sometimes first electrical contact 31 is referred to herein as the first coil contact. Contact 31 is clipped onto stud 31'and mates with third electrical contact 34. Contact 31 is part of the unitary coil and valve assembly 2 and moves therewith when the unitary coil and valve assembly is separated from the body 1. Contact 34 is affixed to the body 1.

Reference numeral 23 illustrates the ultrasonic welding of plate 12 and enclosure 45. Fig. 10 illustrates the energy director 23'and its generally triangular shape (considered in cross-section). Fig. 10 also illustrates energy director 44'on second bobbin 4 and its shape. When ultrasonically welded, the energy directors effectively melt and adhere the enclosure 45 to the second bobbin as indicated by reference numeral 44 and adhere the enclosure 45 to the plate 12 as indicated by reference numeral 23. Enclosure 45 is ultrasonically welded to the plate 12 and to the second bobbin 4. Energy director 44'and energy director 23'focus the energy transmitted during the ultrasonic welding process.

The enclosure 45, plate 12, and body 1 are nylon. Contacts 31 and 34 are beryllium copper and housing 13 and clip 6 are steel. The energy directors 44'and 23'are also nylon.

Fig. 2 is a front view of the solenoid valve illustrating the body and the unitary coil and valve assembly partially in cross-section. Third port 27 and the third passageway 30 of the body 1 are illustrated. Second electrical contact 32, sometimes referred to as the second coil contact, is clipped onto stud 32'. Body mounting bores 40 and 40'enable attachment of the body to the user's structure. Reference numeral 37'is the second electrical lead wire to the coil from the second coil contact 32. Contact 32 is affixed to the unitary

coil and valve assembly and moves therewith.

Figs. 3 and 3A illustrate the second position of spool 8 when the coil is deenergized.

Fig. 3 is a cross-sectional view of the solenoid valve taken along the lines 3-3 of Fig. 1 illustrating the body 1 and the first port 17 in body 1 and the second port 18 in body 1. First nylon bobbin 3 is ultrasonically welded to second nylon bobbin 4 and together comprise the bobbin assembly. Coil 5 is made of insulated copper wire and is wound around second bobbin 4. An overmolded spool 8 includes a portion 9 which is overmolded and an elongated portion 11 which is not overmolded. The spool is aluminum or nylon and the overmolded material of the spool is a rubber. Vent 43 allows for the escape of unwanted air or other gasses which may occur during assembly of the unitary coil and valve assembly 2. Vent 43 allows air above the spool, entrapped above third protrusion 60, to communicate with air below the spool, entrapped below second protrusion 56. This communication allows the pressure of the entrapped air to be applied equally in opposite directions, and the forces on the spool are balanced. Clip 6 is shown in cross-section securing the bobbin 3 and hence the entire unitary coil and valve assembly 2 in place with respect to the body 1. First bobbin 3 is made of nylon and clip 6 is made of steel.

Removal of the unitary coil and valve assembly from the body is accomplished by removing clip 6 from the body 1 (See, Figs. 1, 3 and 10) and simply pulling or separating the unitary coil and valve assembly 2 away from the body.

Referring to Fig. 3, stop 15 and washer 14 are overmolded to second bobbin 4. Stop 15 is made of 430 stainless steel and washer 14 is made of carbon steel. Reference numeral 35 indicates that the second bobbin 4 is ultrasonically welded to nylon plate 12. Fig. 3 illustrates the plunger 10 and

the spool 8 in their respective second positions. In their second positions, flow is permitted between the second port 18 and third port 27 of the body.

Fig. 3A is an enlarged view of a portion of Fig. 3 illustrating the spool and the bobbins. Referring to Fig. 3A, seals 24 and 25 seal the first passageway 49 in the bobbin assembly. The bobbin assembly is a two piece assembly comprised of first bobbin 3 and second bobbin 4 ultrasonically welded together. Reference numeral 57 indicates the ultrasonic welding of first bobbin 3 to second bobbin 4. Seals 25 and 26 seal the second passageway 50 of the bobbin assembly. See, Fig. 9, a cross-sectional view taken along the lines 9-9 of Fig. 2 illustrating the third port 27, the passageway 30 in the body and the third passageway 51 in the bobbin assembly. Fig. 9 illustrates seals 26 and 48 sealing the third passageway. Seals 24,25, 26 and 48 are elastomeric O-ring seals.

Referring to Fig. 3, the coil 5 is not energized and the spool 8 and plunger 10 are in their respective second positions under the urging of spring 7 which urges the spool 8 and the plunger 10 away from the first bobbin 3.

Bobbin 3 has a bore 16 and spring 7 is housed partially in the bore 16. See, Fig. 3A. Annulus 52 is generally bounded by the overmolded portion 9 of spool 8 and the inside bore 54 of bobbin 3. Annulus 52 facilitates communication of fluid flow between the second passageway 50 in the bobbin assembly with third passageway 51 in the bobbin assembly. See, Fig. 9 to view the third passageway 51 in the bobbin assembly.

Figs. 4 and 4A illustrate the first position of the spool when the coil is energized.

Fig. 4 is a cross-sectional view of the solenoid valve similar to the view illustrated in Fig. 3 except the plunger 10 and spool 8 are illustrated in their respective first positions. Fig. 4 illustrates the first port 17 in body 1 communicating with the second port 18 in the body 1. Figs. 3 and 4 both

illustrate a washer 14 overmolded to second bobbin 4. Operator 21 is a polyethylene manual operator which allows for manual operation of the solenoid valve if desired. Seal 20 seals the operator against the interior bore of the second bobbin. Operator 21 is restrained in its downward movement toward the body by the plunger 10. Enclosure 45 captures and retains the operator from exiting the assembly. Figs. 3 and 4 illustrate the unitary coil and valve assembly flush against the body 1. Reference numeral 22 indicates the engagement of the unitary coil and valve assembly with the body 1. Fig.

4A illustrates an annulus between the spool 8 and the second bobbin 4.

Reference numeral 53 indicates the annulus which permits flow between the first port 17 and the second port 18.

Figs. 3 and 3A depict the valving action of the spool with respect to the bobbin assembly when the coil 5 is deenergized. In particular, protrusion 55 engages shoulder 59 of the bobbin assembly to prohibit flow to the second passageway 50 of the bobbin assembly. Reference numeral 61 indicates the flow path from the second passageway 50 of the bobbin assembly to the third passageway 51 of the bobbin assembly. See, Fig. 9. Figs. 4 and 4A depict the valving action of the spool with respect to the bobbin assembly when the coil 5 is energized. In particular, protrusion 55 engages shoulder 58 of the bobbin assembly to prohibit flow to the third passageway 51 of the bobbin assembly.

Reference numeral 62 represents the flow path from the first passageway 49 to the second passageway 50 of the bobbin assembly. Figs. 3A and 4A illustrate seals 26 and 48 for sealing the third passageway 51 in the bobbin assembly.

Referring to Figs. 3A and 4A, the overmolded portion 9 of spool 8 includes a first protrusion 55, a second protrusion 56 and a third protrusion 60.

Spool 8, in its second position as illustrated in Fig. 3A, may have pressure applied to annulus 53, first protrusion 55 and third protrusion 60. Protrusions 55 and 60 have approximately the same pressurized cross-sectional area and

are exposed to any fluid pressure within the annulus 53 and as a result the spool is substantially pressure balanced. Similarly, spool 8, in its first position as illustrated in Fig. 4A, may have pressure applied to annulus 52, first protrusion 55 and third protrusion 56. Protrusion 55 and 56 have approximately the same pressurized cross-sectional area exposed to any fluid pressure within annulus 52 and, as a result, the spool is substantially pressure balanced.

The overmolded portion 9 of the spool 8 provides a seal against fluid pressure. For instance, referring to Figs. 3A and 4A third protrusion 60 and second protrusion 56 prevent the escape of fluid flow into unwanted areas past protrusion 60 and 56 and above or below the overmolded portions of the spool.

Fig. 5 illustrates the unitary coil and valve assembly 2. Reference numerals 41 and 41'represent the first and second slots respectively in the first bobbin 3. These slots 41 and 41'in combination with the clip 6 retain the unitary coil and valve assembly 2 in position with respect to the body 1.

Fig. 6 is a cross-sectional view of the body 1. Reference numerals 46 and 47 are the first and second bores in the body 1 for receiving the clip 6.

Fig. 6 also illustrates the first mounting hole 40 and second mounting hole 40' for affixing the body 1 of the solenoid valve to the structure of the user. Fig 6 also shows the first passageway 28 in the first port 17 and the second passageway 29 in the second port 18.

Fig. 7 is a sectional view taken along the line 7-7 of Fig. 2 illustrating the first port 17 as well as one of the electrical contacts 31 of the unitary coil and valve assembly and one of the electrical contacts 34 of the body 1. Body 1 includes stud 34'to which electrical contact 34 is clipped onto and held in place by the friction of the contact against the stud. An O-ring 36 seals the plate 12 with respect to the body 1. When the unitary coil and valve assembly

2 is affixed to the body 1 the contacts 34 and 31 mutually engage producing a pathway for electrical current to flow. Reference numeral 38 indicates a power lead from a power source to the contact 34.

Fig. 8 is a view taken along the lines 8-8 of Fig. 2 illustrating the body and second port 18 in cross-section as well as the fourth electrical contact 39, affixed to stud 39'of the body. The second electrical contact 32 is shown affixed to the stud 32'in the unitary coil and valve assembly. 0-ring 36'is illustrated for sealing the contacts 32 and 39 when the unitary coil and valve assembly mates with the body 1. Contacts 32 and 39 conduct electric current when the unitary coil and valve assembly mates with the body as do contacts 31 and 34. Of course, another device controls the application of power to the coil 5.

Fig. 9 illustrates a cross-sectional view taken along the lines 9-9 of Fig.

2 illustrating the third port 27, the third passageway 30 in the third port 27, and the third passageway 51 in the bobbin assembly. Fig. 9 illustrates the communication between the second and third ports of the body when the plunger and spool are in their respective second positions.

Fig. 10 is an isometric view of the unitary coil and valve assembly 2.

Fig. 10 illustrates an isometric view of a portion of the unitary coil and valve assembly. Passageways 30 and 49 are illustrated in the bobbin assembly and the energy directors 23'and 44'are best seen in this view.

A novel process for assembling the unitary coil and valve assembly is disclosed herein. Referring to Fig. 3, the spool and its elongated portion 11 is a one piece assembly. The one piece spool assembly minimizes the tolerance buildup which occurs in traditional solenoid valve constructions where a push pin is used in combination with a spool. The engagement of the spool with the plunger as illustrated in Fig. 3 insures that the plunger and spool can travel far enough from their second positions as shown in Fig. 3 to their first positions

as shown in Fig. 4 without the plunger interfering with (i. e. engaging) stop 15.

Stop 15 is overmolded to bobbin 4 and the tolerances of the stop relative to the bobbin are thus well controlled.

The steps of assembling the unitary coil and valve assembly include : overmolding a stop 15 to a second bobbin 4 ; overmolding rubber onto the spool ; installing the spool in said second bobbin and said stop ; installing a spring in the bore of the spool ; welding a first bobbin 3 to the second bobbin 4 to form a bobbin assembly, welding the bobbin assembly to the plate ; and affixing the bobbin assembly to the body. Fig. 11 illustrates the process steps.

The foregoing description of the invention is set forth by way of example only and is not intended to limit the scope and coverage of the claims which follow hereinbelow. Those skilled in the art will readily recognize that several modifications and changes may be made to the foregoing invention without departing from the spirit and the scope of the claims which follow below.