FLUX COLLECTOR WITH INTERCONNECTED PORTIONS AND METHOD OF
MANUFACTURING SOLENOID VALVE ASSEMBLY HAVING SAME
TECHNICAL FIELD
[0001] The present teachings generally include a flux collector and a method of
manufacturing a solenoid valve assembly having a flux collector.
BACKGROUND
[0002] Solenoid valves sometimes have a coil that can carry current to create an
electromagnetic flux field, causing movement of an armature within the valve. Flux
collectors are sometimes placed adjacent the coil around the armature to collect the flux,
thereby directing the magnetic field to aid in movement of the armature.
SUMMARY
[0003] An apparatus such as for a solenoid valve assembly includes a substantially
annular flux collector that has a first arced portion and at least one additional arced
portion. The first arced portion and the at least one additional arced portion are
cooperatively configured to interlock with one another to form the substantially annular
flux collector.
[0004] The annular flux collector can be used in a solenoid valve assembly that has a
valve body with a groove on an outer surface of the valve body. The first arced portion
and the at least one additional arced portion are cooperatively configured to interlock
with one another to form the substantially annular flux collector when inserted into the
groove to surround the valve body at the groove. A movable armature is inside of the
valve body radially inward of the flux collector.
[0005] A method of manufacturing a solenoid valve assembly includes inserting the
arced portions of the flux collector into an external groove of a valve body such that the
arced portions interlock with one another to encircle the valve body at the groove and
form an annular flux collector. The valve body can be turned, with the groove cut into an
external surface of the valve body. The annular flux collector thus need not be cast
integrally with the valve body.

[0006] The above features and advantages and other features and advantages of the
present teachings are readily apparent from the following detailed description of the best
modes for carrying out the present teachings when taken in connection with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIGURE 1 is a schematic illustration in perspective view of an arced portion
of an annular flux collector.
[0008] FIGURE 2 is a schematic illustration in perspective view of an annular flux
collector formed by the arced portion of Figure 1 interlocked with another arced portion.
[0009] FIGURE 3 is a schematic illustration in fragmentary plan view of a slot of the
arced portion of Figure 1.
[0010] FIGURE 4 is a schematic illustration in fragmentary plan view of a protrusion
of the arced portion of Figure 1.
[0011] FIGURE 5 is a schematic illustration in front view of the first arced portion of
Figure 1.
[0012] FIGURE 6 is a schematic cross-sectional illustration of a solenoid valve
assembly including the annular flux collector of Figure 2, taken at lines 6-6 in Figure 7.
[0013] FIGURE 7 is a schematic perspective illustration of the solenoid valve
assembly of Figure 6.
[0014] FIGURE 8 is a schematic illustration of a work piece undergoing a turning
operation to form a valve body of the solenoid valve assembly of Figures 6 and 7.
[0015] FIGURE 9 is schematic side view illustration of the valve body of Figures 6
and 7 after the turning operation of Figure 8 and showing a groove cut into an external
surface.
[0016] FIGURE 10 is a schematic illustration in perspective view of a portion of the
solenoid valve assembly of Figures 6 and 7, showing the flux collector placed in the
groove on the valve body.
[0017] FIGURE 11 is a schematic plan view of a valve housing of the solenoid valve
of Figure 6.

[0018] FIGURE 12 is a flow diagram of a method of manufacturing the solenoid
valve assembly of Figures 6 and 7.
DETAILED DESCRIPTION
[0019] Referring to the drawings, wherein like reference numbers refer to like
components throughout the several views, Figure 1 shows a first arced portion 10 of an
apparatus referred to as an annular flux collector 12, shown in Figure 2. As shown in
Figure 2, the first arced portion 10 is configured to interlock with a second arced portion
14 to form the annular flux collector 12. Although only two arced portions 10, 14 form
the annular flux collector 12, within the scope of the present teachings, three or more
arced portions could be configured to interlock with one another to form the annular flux
collector. The arced portions 10, 14 can be steel or any other material capable of being
magnetized to carry magnetic flux.
[0020] The annular flux collector 12 can be used in a solenoid valve assembly 16
shown in Figure 6, although its use is not limited to a solenoid valve assembly. As
explained herein, the configuration of the annular flux collector 12 enables the use of a
turned valve body 18, although a cast valve body or a valve body made according to a
different process may instead be used. One method 200 of manufacturing the solenoid
valve assembly 16 is described with respect to a flow diagram in Figure 12, and is
discussed herein.
[0021] The first arced portion 10 shown in Figure 1 has a first end 20 with a first
shape and a second end 22 with a second shape. Specifically, the first shape of the first
end 20 is defined by a first radially-extending surface 24 with a first feature, such as a
slot 26 extending from the surface 24. The second shape of the second end 22 is defined
by a second radially-extending surface 28 with a second feature, such as a protrusion 30
extending from the surface 28.
[0022] The slot 26 and the protrusion 30 are one example of first and second features
that may be used within the scope of the present teachings. The shapes of the first and
second ends 20, 22 of the first arced portion 10 may be defined by other first and second
features, respectively, that are designed to interlock with one another.

[0023] Figure 3 shows the slot 26 has an opening 32 with projections 34 extending
inward at the opening 32 such that the slot 26 is narrowed at the opening 32 by the
projections 34. Figure 4 shows the protrusion 30 has flared sides 31 and a tapered neck
33 that forms the notches 37 at the surface 28. The slot 26 and the protrusion 30 are
cooperatively configured so that a distance Dl of the narrowest portion between the
projections 34 is substantially equal to a width D2 of the narrowest portion of the tapered
neck 33.
[0024] Figure 2 shows that the second arced portion 14 has an end 35, referred to as a
third end, with a third shape partially defined by a third feature that is a slot 36. The
second arced portion 14 has another end 39, referred to as a fourth end with a fourth
shape partially defined by a fourth feature that is a protrusion 38. In the embodiment
shown, the second arced portion 14 is substantially identical to the first arced portion 10.
Accordingly, the third shape of the third end 35 is substantially identical to the first shape
of the first end 20 and the fourth shape of the fourth end 39 is substantially identical to
the second shape of the second end 22. The slot 36 has an opening and projections as
described with respect to the slot 26. The protrusion 38 has flared sides and a tapered
neck as described with respect to the protrusion 30.
[0025] As shown in Figure 2, the protrusion 30 is configured to fit within the slot 36
when pressed into the slot 36 with sufficient force to cause the flared sides 31 to slide
past the projections 34 so that the projections 34 rest in the notches 37 of the tapered neck
33. This locks the protrusion 30 within the slot 36 and interlocks the first arced portion
10 and the second arced portion 14. At the same time, the protrusion 38 is similarly
pressed into the slot 26, locking the protrusion 38 into the slot 26 and further interlocking
the first arced portion 10 and the second arced portion 14. The protrusion 30 can be
pressed into the slot 36 in a direction substantially perpendicular to a center axis C of the
assembled annular flux collector 12. The force required to press the protrusions 30, 38
into the slots 26, 36 can cause mechanical deformation of either or both of the protrusions
30, 38 and the slots 26, 36. Specifically, the projections 34 can be at least slightly
deformed when the flared sides 31 are forced past the projections 34.
[0026] The first arced portion 10 has an inner arced surface 40 and the second arced
portion 14 has an inner arced surface 42. When the arced portions 10, 14 are interlocked,

the inner arced surfaces 40, 42 together define an inner periphery 44 of the flux collector
12. The first arced portion 10 and the second arced portion 14 each extend in an axial
direction (upward along axis C in the view of Figure 2) to define a collar 46 when the
arced portions 10, 14 are interlocked. The collar 46 has a first collar portion 48 of the
first arced portion 10 and a second collar portion 50 of the second arced portion 14. The
collar 46 has a height HI along the axis C. A surface 52 of the first arced portion 10
opposite the collar 46 and a surface 54 of the second arced portion 14 opposite the collar
46 are both substantially flat, as best shown in Figures 5 and 6.
[0027] Figure 6 shows the solenoid valve assembly 16 supported on a mounting
bracket 60. For example, the mounting bracket 60 can be secured to a camshaft cover on
an engine when the solenoid valve is used as an oil control valve retarding or advancing
engine timing. The mounting bracket 60 is welded to a valve housing 62 that contains
the flux collector 12 as described herein.
[0028] As shown in Figure 11, the valve housing 62 is hollow, with an inner cavity
64 that has an inner diameter D3. The valve housing 62 has a central opening 66 at one
end. The central opening 66 has a second inner diameter D4 that is smaller than the inner
diameter D3 so that the valve housing 62 forms a flange 63 that extends radially inward
around the central opening 66. Figure 6 shows a coil 70, a pole piece 72 and a bobbin 74
that are packaged within the valve housing 62, along with the annular flux collector 12.
The flux collector 12 is fit within a groove 71 formed on an outer surface 73 of the valve
body 18 as described herein. The bobbin 74 is over-molded by injection molding with
mold portion 76. The bobbin 74 surrounds the coil 70. The pole piece 72 is press-fit or
otherwise secured within the bobbin 74 and is fit within a columnar cavity 75 in the valve
body 18 and secured by a seal 77. A cap 78 is placed over the bobbin 74 and around the
pole piece 72. The valve housing 62 is formed with integral securing tabs 80 at an end of
the housing 62. The tabs 80 are shown in a pre-assembly or pre-crimped position 80A in
phantom in Figure 7.
[0029] Figure 6 shows an armature 82 that is movable within the cavity 75 in
response to electromagnetic flux. The pole piece 72, coil 70, flux collector 12 and
armature 82 form an electromagnet. Lines of flux are created in an air gap 81 between
the pole piece 72 and the armature 82 when the coil 70 is energized by an electric source

(such as a battery, not shown). The armature 82 is movable within the cavity 75 defined
by the valve body 18 in response to the flux created by energizing the coil 70. The flux
collector 12 is positioned in close radial proximity to the armature 82 to enable the
magnetic flux to ensure fast and accurate responsiveness of the armature 82 to energizing
and deenergizing of the coil 70. A valve stem 84 is press-fit to the armature 82 and
moves with the armature 82. A poppet 86 is fit to the end of the valve stem 84. An
extension 19 is threaded to the valve body 18 and partially houses a distal end of the stem
84 in a cavity 79 that is in communication with the cavity 75.
[0030] The armature 82 is shown in a first position in which the coil 70 is
deenergized. When the armature 82 is in the first position shown, a control passage 88 is
in fluid communication with an exhaust passage 90 to allow fluid at a control pressure to
exhaust through the valve body 18 when fluid force overcomes a ball check valve 91. A
supply passage 92 is blocked from fluid communication with the exhaust passage 90 as
the valve stem 84 is seated at a first valve seat 94. A wire mesh filter 93 covers the
supply passage 92. The filter 93 is permeable to permit fluid to flow to the supply
passage 92. When the coil 70 is energized, the armature 82 moves toward the pole piece
72, causing the valve stem 84 to also move upward until the poppet 86 is seated at a
second valve seat 95. The supply passage 92 is then in fluid communication with the
control passage 88, to direct fluid through the control passage 88. The supply passage 92
is not in fluid communication with the exhaust passage 90 when the coil 70 is energized.
[0031 ] After the cap 78 is placed in the housing 62, the tabs 80 are crimped
downward to the positions shown in Figures 6 and 7 to tightly secure the components
within the valve housing 62. Figure 6 shows that an inner surface 96 of the bobbin 74
has a shape that is complementary to an outer surface 97 of the flux collector 12. The
extension of the collar 46 and contact with the bobbin 74 ensures that the collar 46 will
have a moment arm to prevent the radially-outer portions of the flux collector 12 from
rotating upward when the tabs 80 are crimped downward. This ensures that the flux
collector 12 stays in position against the valve body 18, as close as possible in a radial
direction to the armature 82.
[0032] The flux collector 12 is configured to allow the valve body 18 to be separately
manufactured rather than cast with a flux collector in the casting mold. Specifically,

Figure 8 shows a generally cylindrical aluminum work-piece 100 held in a machine tool
such as a CNC lathe 102. The lathe 102 has a variety of computer-controlled cutting
mechanisms used to form the valve body 18, shown in Figure 9. A cutting tool 104 is
used to cut and define the outer surface of the finished valve body 18, including the
groove 71 in which the flux collector 12 is seated, as shown in Figures 6 and 10. Figure
9 shows the finished valve body 18 with the groove 71 as well as the supply passage 92
and the control passage 88.
[0033] Figure 12 is a flow diagram of a method 200 of manufacturing the solenoid
valve assembly 16 of Figure 6. The method 200 begins with block 202 in which a
generally cylindrical work-piece 100 is turned to create a valve body 18. In block 204, a
groove 71 is cut in an external surface of the valve body 18. The arced portions 10, 14 of
an annular flux collector 12 are then inserted into the groove 71 in block 206 to interlock
the portions 10, 14 to one another to form the annular flux collector 12. The arced
portions 10, 14 are inserted in a generally radially-inward direction into the groove 71,
perpendicular to a center axis C2 of the valve body 18, shown in Figure 10. An axial
height H2 of the groove 71, shown in Figure 9, is greater than the axial height HI of the
annular flux collector 12, shown in Figure 2, so that the flux collector 12 can fit within
the groove 71. Because the portions 10, 14 are designed to interlock, they cannot separate
by vibrating radially-outward as they are handled prior to insertion into the valve housing
62. This ensures that the annular flux collector 12 will fit within the cavity 64. The outer
diameter D5 of the annular flux collector 12 is only slightly less than the inner diameter
D3 of the valve housing 62, so the prevention of radial separation enabled by the
interlocked portions 10, 14 ensures that the flux collector 12 will be insertablc into the
valve housing 62. Any radially-outward propagation of the flux collector 12 could
compromise the ability of the valve body 18 with attached flux collector 12 to fit into the
valve housing 62.
[0034] In block 208 shown in Figure 12, the assembled coil 70 and bobbin 74 are
pressed onto the valve body 18. Next, in block 210, the valve body 18 with the flux
collector 12, coil 70 and over-molded bobbin 74 are pressed into the housing 62. The
valve body 18 will extend through the central opening 66, while the flux collector 12 will
rest against the flange 63. In block 212, the cap 78 is then inserted over the over-molded

bobbin 74. In block 214, the securing tabs 80 are pressed downward to crimp the valve
housing 62 around the flux collector 12, coil 70 and bobbin 74.
[0035] The reference numbers used in the drawings and the specification along with
the corresponding components or method steps is as follows:
10 first arced portion
12 annular flux collector
14 second arced portion
16 solenoid valve assembly
18 turned valve body
19 extension
20 first end of 10
22 second end of 10
24 radially-extending surface
26 slot
28 second radially-extending surface
30 protrusion
31 flared sides
32 opening
33 tapered neck
34 projections
35 end of 14 (third end)
36 slot
37 notches
38 protrusions
39 end of 14 (fourth end)
40 inner arced surface of 10
42 inner arced surface of 14
44 inner periphery
46 collar
48 first collar portion
50 second collar portion
52 surface
54 surface
60 mounting bracket
62 valve housing
63 flange
64 inner cavity
66 central opening

70 coil
71 groove
72 pole piece
73 outer surface
74 bobbin
75 columnar cavity

76 mold portion
77 seal
78 cap
79 cavity
80 security tabs
80A pre-crimped position
81 air gap
82 armature
84 valve stem
86 control passage
88 control passage
90 exhaust passage
91 ball check valve
92 supply passage
93 wire mesh filter
94 first valve seat
95 second valve seat
96 inner surface
97 outer surface
100 work-piece
102 lathe
104 cutting tool
200 method
202 turning step
204 cutting step
206 inserting arced portions step
208 pressing assembled coil and bobbin step
210 inserting valve body step
212 inserting cap step
214 pressing tabs step
HI axial height of collar
H2 axial height of groove
D1 distance between projections
D2 width of tapered neck
D3 diameter of inner cavity of valve housing
D4 diameter of central opening of valve housing
D5 outer diameter of annular flux collector
[0036] While the best modes for carrying out the many aspects of the present
teachings have been described in detail, those familiar with the art to which these
teachings relate will recognize various alternative aspects for practicing the present
teachings that are within the scope of the appended claims.

We Claim:
1. An apparatus comprising:
a flux collector (12) having:
a first arced portion(10);
at least one additional arced portion (14); wherein the first arced
portion and said at least one additional arced portion are cooperatively configured to
interlock with one another so that the flux collector is substantially annular.
2. The apparatus of claim 1, wherein the first arced portion and said
at least one additional arced portion are configured to interlock by deformation.
3. The apparatus of claim 1, wherein said at least one additional arced
portion is a single, second arced portion that is substantially identical to the first arced
portion.
4. The apparatus of claim 3, wherein the first arced portion and the
second arced portion each have a first feature (26) at a first radially-extending surface
(24) of a first end (20) and a second feature (30 at a second radially-extending surface
(28) of a second end (22);
wherein the second feature of the second arced portion is configured to
deform the first arced portion at the first feature of the first arced portion and the second
feature of the first arced portion is configured to deform the second arced portion at the
first feature of the second arced portion to thereby interlock the first arced portion and the
second arced portion.
5. The apparatus of claim 4, wherein the first feature of the first arced
portion and the first feature of the second arced portion are each a slot (26) having
projections (34) extending inward at an opening (26) of the slot; wherein the second
feature of the first arced portion and the second feature of the second arced portion are

each protrusions (30); wherein the projections are configured to be deformed by the
protrusions when the protrusions are placed within the slots.
6. The apparatus of claim 1, wherein the first arced portion (10) and
said at least one additional arced portion (14) each have an inner arced surface (40, 42)
that partially defines an inner periphery (44) of the flux collector when the arced portions
are interlocked with one another; and
wherein the first arced portion and said at least one additional arced
portion each extend in one axial direction at said inner arced surface to define a collar
(46) when the arced portions are interlocked with one another.
7. An apparatus comprising:
a valve body (18) having a groove (71) on an outer surface (73) of the
valve body;
a substantially annular flux collector (12) having:
a first arced portion (10); and
at least one additional arced portion (14);
wherein the first arced portion and said at least one additional arced
portion are cooperatively configured to interlock with one another to form the
substantially annular flux collector when inserted into the groove to surround the valve
body at the groove; and
a movable armature (82) inside of the valve body radially inward of the
flux collector.
8. The apparatus of claim 7, wherein said at least one additional arced
portion is a single, second arced portion (14); wherein the first arced portion and the
second arced portion each have a slot (26) at a first radially-extending surface (24) of a
first end (20) and a protrusion (30) at a second radially-extending surface (28) of a
second end (22);

wherein the protrusion of the second arced portion is configured to deform
the first arced portion at the slot of the first arced portion and the protrusion of the first
arced portion is configured to deform the second arced portion at the slot of the second
arced portion to thereby interlock the first arced portion and the second arced portion.
9. The apparatus of claim 7, wherein the first arced portion (10) and
the second arced portion (14) each have an inner arced surface (40, 42) that partially
defines an inner periphery (44) of the flux collector when the arced portions are
interlocked with one another; and
wherein the first arced portion and the second arced portion each extend in
one axial direction at said inner arced surface to define a collar (46) when the arced
portions are interlocked with one another; wherein an axial height (H1) of the collar fits
within an axial height (H2) of the groove.
10. The apparatus of claim 9, further comprising:
a valve housing (62) defining an inner cavity (64) having an inner
diameter (D3) and a central opening (66) at one end; wherein the central opening has a
second diameter (D4) smaller than the inner diameter so that the valve housing forms a
flange (63) around the central opening;
wherein the flux collector has an outer diameter (D5) smaller than the
inner diameter and larger than the central opening so that the valve body extends through
the central opening and the flux collector resting against the flange of the valve housing.
11. The apparatus of claim 10, further comprising:
a pole piece (72), a bobbin (74) containing a coil (70) and surrounding the
pole piece; wherein the coil is energizable to move the armature within the flux collector;
wherein the valve housing is crimped to retain the flux collector, the coil, the pole piece,
and the bobbin within the cavity.

12. A method (200) of manufacturing a solenoid valve assembly (16)
comprising:
inserting (206) arced portions (10, 14) of a flux collector (12) into an
external groove (71) of a valve body (18) such that the arced portions interlock with one
another to encircle the valve body at the groove and form an annular flux collector.
13. The method of claim 12, further comprising:
turning (202) a work-piece (100) to form the valve body; and
cutting (204) the groove in the valve body.
14. The method of claim 12, further comprising:
inserting (210) the valve body with the flux collector thereon into a cavity
(64) of a valve housing (62) such that the valve body extends through an opening (66) of
the valve housing and the flux collector rests on the valve housing inside the cavity.
15. The method of claim 12, further comprising:
assembling (208) a bobbin, a coil, and a pole piece within the valve
housing; and
crimping (214) the valve housing around the bobbin, the coil, the pole
piece and the flux collector.