Title: Solenoid coil assembly
Abstract: A coil assembly includes a spool having a wire wound therearound to establish a coil. A spool terminal extends from the spool and the end of the wire is wound around the spool terminal. A connector housing is coupled to the spool and a connector terminal extends therefrom. A portion of the connector terminal is adjacent to a portion of the spool terminal. Thus, the connector terminal can be relatively easily resistance welded or soldered to the spool terminal.
Patent Number: 6,864,775 Issued on 03/08/2005 to Lopez, et al.
| Inventors:
|
Lopez; Jorge L. (Chihuahua, MX);
Burrola; Santos (Chihuahua, MX);
Concha; Miguel A. (Chihuahua, MX);
Rodriguez; Luis E (Chihuahua, MX)
|
| Assignee:
|
Delphi Technologies, Inc. (Troy, MI)
|
| Appl. No.:
|
666713 |
| Filed:
|
September 18, 2003 |
| Current U.S. Class: |
336/192; 336/107; 336/198 |
| Intern'l Class: |
H01F 027//30 |
| Field of Search: |
336/65,83,90,92,107,192,198
439/874,867-873
|
References Cited [Referenced By]
U.S. Patent Documents
Primary Examiner: Nguyen; Tuyen T.
Attorney, Agent or Firm: Funke; Jimmy L.
Parent Case Text
This is a division of application Ser. No. 10/265,966 filed on Oct. 7, 2002
now U.S. Pat. No. 6,680,666.
Claims
We claim:
1. A terminal assembly, comprising:
at least one electrical device;
at least one electrical device terminal extending from the electrical
device;
at least one wire wound at least partially around the electrical device
terminal;
at least one connector device coupled to the electrical device; and
at least one connector device terminal extending from the connector device,
at least a portion of the connector device terminal being adjacent to at
least a portion of the electrical device terminal and electrically
connected thereto, the connector terminal including a lower connector
terminal portion extending from within the housing, a lateral connector
terminal portion extending perpendicularly from the lower connector
terminal portion, and an upper connector terminal portion extending
perpendicularly from the lateral connector terminal portion away from the
lower connector terminal portion and housing.
2. The terminal assembly of claim 1, further comprising:
at least a first arm extending from the connector device terminal such that
it flanks the electrical device terminal.
3. The terminal assembly of claim 2, further comprising:
at least a second arm extending from the connector device terminal such
that it flanks the electrical device terminal.
4. The terminal assembly of claim 3, wherein the electrical device terminal
is at least partially between the first and second arms.
5. The terminal assembly of claim 4, wherein the electrical device terminal
is at least partially resistance welded to the first and second arms.
6. The terminal assembly of claim 4, wherein the electrical device terminal
is at least partially soldered to the first and second arms.
Description
TECHNICAL FIELD
The present invention relates to solenoids and actuators.
BACKGROUND OF THE INVENTION
Modern motor vehicles are equipped with numerous vehicle subsystems that
are designed to increase the comfort and safety of drivers and passengers.
For example, a vehicle can include an anti-lock braking system, a traction
control system, a speed control system, and/or a vehicle stability
enhancement control system. In turn, each subsystem can include numerous
electromagnetic sensors and/or actuators that utilize electric coil
assemblies to move plungers when energized or to provide control signals
in response to changes in magnetic flux around the sensing coils.
In general, these coil assemblies include a plastic "I" shaped spool having
a winding bay established around it. A coil of wire is formed within the
winding bay. The spool is mated with a connector housing having one or
more terminals to which the coil is electrically connected. Typically,
during manufacturing, the spool is loaded into a winding machine that
automatically winds a thin wire around the spool within the winding bay in
order to form the coil. The ends of the wire are manually stripped and
wrapped around connector terminals. Thereafter, the ends of the wire are
manually soldered to the connector terminals. It can be appreciated that
the manual steps increase manufacturing time and costs.
The present invention has recognized the prior art drawbacks, and has
provided the below-disclosed solutions to one or more of the prior art
deficiencies.
SUMMARY OF THE INVENTION
A coil assembly includes a spool having a wire wound around it to establish
a coil. A spool terminal extends from the spool and a portion of the wire
is wound around the spool terminal. A connector housing is coupled to the
spool and a connector terminal extends from the connector housing. A
portion of the connector terminal is adjacent to a portion of the spool
terminal and is electrically connected thereto.
In one aspect of the present invention, a first arm extends from the
connector terminal such that it flanks the spool terminal. Moreover, a
second arm extends from the connector terminal such that flanks the spool
terminal. Thus, the spool terminal is between the first and second arms.
In another aspect of the present invention, the spool defines a top and the
spool terminal extends perpendicularly from the top of the spool. Also,
the connector housing defines a top and the connector terminal includes a
lower connector terminal portion that extends perpendicularly from the top
of the connector housing. A lateral connector terminal portion extends
perpendicularly from the lower connector terminal portion toward the
spool. Also, an upper connector terminal portion extends perpendicularly
from the lateral connector terminal portion such that it is parallel and
adjacent to the spool terminal. In this aspect, the first arm and the
second arm extend perpendicularly from the upper connector terminal
portion around the spool terminal and the spool terminal is electrically
connected to the connector terminal by resistance welding or soldering.
In yet another aspect of the present invention, the spool defines a top and
the spool terminal includes a lower spool terminal portion that extends
perpendicularly from the top of the spool. Moreover, an upper spool
terminal portion extends perpendicularly from the lower spool terminal
portion toward the connector housing. The connector housing defines a top
and the connector terminal includes a lower connector terminal portion
that extends perpendicularly from the top of the connector housing. Also,
an upper connector terminal portion extends perpendicularly from the lower
connector terminal portion such that it is parallel and adjacent to the
spool terminal. In this aspect the first arm and the second arm extend
perpendicularly from the upper connector terminal portion around the spool
terminal. Also, the spool terminal is electrically connected to the
connector terminal by resistance welding or soldering.
In still another aspect of the present invention, the spool defines a top
and the spool terminal extends perpendicularly from the top of the spool.
Also, the connector housing defines a top and the connector terminal
comprises a lower connector terminal portion extends perpendicularly from
the top of the connector housing. A lateral connector terminal portion
extends perpendicularly from the lower connector terminal portion toward
the spool and an upper connector terminal portion extends perpendicularly
from the lateral connector terminal portion such that it is parallel and
adjacent to the spool terminal. Thus, the spool terminal can be resistance
welded or soldered to the connector terminal.
In yet still another aspect of the present invention, a terminal assembly
includes an electrical device. An electrical device terminal extends from
the electrical device. A portion of a wire is wound around the electrical
device terminal. A connector device is coupled to the electrical device
and a connector device terminal extends from the connector device. A
portion of the connector device terminal is adjacent to a portion of the
electrical device terminal and is electrically connected thereto.
The present invention will now be described, by way of example, with
reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with
reference to the accompanying drawings, in which:
FIG. 1 is a side plan view of a coil assembly;
FIG. 2 is a top plan view of the coil assembly shown in FIG. 1;
FIG. 3 is a side plan view of an alternative coil assembly;
FIG. 4 is a top plan view of the coil assembly shown in FIG. 3; and
FIG. 5 is a side plan view of a second alternative coil assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, a coil assembly is shown and generally
designated 10. FIGS. 1 and 2 show that the coil assembly 10 includes a
preferably "I" shaped spool 12 around which a relatively thin, preferably
copper wire 14 is wound to form a coil 16. As shown, at least one, but
preferably two spool terminals 18 extend perpendicularly from the top of
the spool 12 such that they are parallel to a longitudinal axis 20 defined
by the coil assembly. In a preferred embodiment, the spool terminals 18
have a cross-section that is square. The wire 14 defines two ends 22 and
each end 22 of the wire 14 is wrapped around a respective spool terminal
18.
FIGS. 1 and 2 show that the coil assembly 10 also includes a connector
housing 24 that is mechanically coupled to the spool 12. As shown, the
connector housing 24 forms an internal cavity 26 that is sized and shaped
to receive a male electrical connector that can be electrically connected
to a vehicle control system. Moreover, the connector housing 24 includes
at least one, but preferably two connector terminals 28.
It is to be understood that the connector terminals 28 are identical to
each other and that each includes a lower connector terminal portion 30
that extends from within the cavity 26 through the connector housing 24
and beyond the top thereof. As shown, the lower connector terminal portion
30 of each connector terminal 28 is parallel to the longitudinal axis 20
of the coil assembly 10. A lateral connector terminal portion 32 extends
perpendicularly from the lower connector terminal portion 30 toward the
spool 12. Moreover, an upper connector terminal portion 34 extends
perpendicularly from the lateral connector terminal portion 32 in an
upward direction such that it is parallel to the longitudinal axis 20. It
is to be understood that when the connector housing 24 is coupled to the
spool 12, the upper connector terminal portion 34 of each connector
terminal 28 is slightly spaced from a respective spool terminal 18.
FIGS. 1 and 2 show that a first arm 36 and a second arm 38 extend
perpendicularly from the upper connector terminal portion 34 of each
connector terminal 28 such that the arms 36, 38 of each connector terminal
28 flank a respective spool terminal 18 when the connector housing 24 is
mechanically coupled to the spool 12. It can be appreciated that the arms
36, 38 of each connector terminal 28 are spaced a distance, d, from each
other that is slightly larger that the width of a spool terminal 18 plus
twice the diameter of the wire end 22 that is wound around the spool
terminal 18. Accordingly, during assembly, when the spool 12 is coupled to
the connector housing 24 the arms 36, 38 of each connector terminal 28 fit
around a respective spool terminal 18 and are preferably resistance welded
thereto.
Referring now to FIGS. 3 and 4, an alternative coil assembly is shown and
generally designated 50. FIGS. 3 and 4 show that the coil assembly 50
includes a preferably "I" shaped spool 52 around which a relatively thin,
preferably copper wire 54 is wound to form a coil 56. As shown, at least
one, but preferably two spool terminals 58 extend from the top of the
spool 52. As shown, each spool terminal 58 includes a lower spool terminal
portion 59 that extends from the top of the spool 52 such that it is
parallel to a longitudinal axis 60 defined by the coil assembly 50. Also,
each spool terminal 58 includes an upper spool terminal portion 61 that
extends radially from the lower spool terminal portion 59 such that it is
perpendicular to the longitudinal axis 60. It is to be understood that the
wire 54 defines two ends 62 and each end 62 of the wire 54 is wrapped
around a respective spool terminal 58.
FIGS. 3 and 4 show that the coil assembly 50 also includes a connector
housing 64 that is mechanically coupled to the spool 52. As shown, the
connector housing 64 forms an internal cavity 66 that is sized and shaped
to receive a male electrical connector leading to and from a vehicle
control system. Moreover, the connector housing 64 includes at least one,
but preferably two connector terminals 68.
It is to be understood that the connector terminals 68 are identical to
each other and that each includes a lower connector terminal portion 70
that extends from within the cavity 66 through the connector housing 64
and beyond the top thereof. As shown, the lower connector terminal portion
70 of each connector terminal 68 is parallel to the longitudinal axis 60
of the coil assembly 50. An upper connector terminal portion 74 extends
perpendicularly from the lower connector terminal portion 70 toward the
spool 52. It is to be understood that when the connector housing 64 is
coupled to the spool 52, the upper connector terminal portion 74 of each
connector terminal 68 is beneath and slightly spaced from a respective
spool terminal 58.
FIGS. 3 and 4 show that a first arm 76 and a second arm 78 extend
perpendicularly from the upper connector terminal portion 74 of each
connector terminal 68 such that the arms 76, 78 of each connector terminal
68 flank a respective spool terminal 58 when the connector housing 64 is
mechanically coupled to the spool 52. It can be appreciated that the arms
76, 78 of each connector terminal 68 are spaced a distance, d, from each
other that is slightly larger that the width of a spool terminal 58 plus
twice the diameter of the wire end 62 wound therearound. Accordingly,
during assembly, when the spool 52 is coupled to the connector housing 64
the arms 76, 78 of each connector terminal 76 fit around a respective
spool terminal 58 and are preferably resistance welded thereto.
Referring to FIG. 5, a coil assembly is shown and generally designated 100.
FIG. 5 shows that the coil assembly 100 includes a preferably "I" shaped
spool 102 around which a relatively thin, preferably copper wire 104 is
wound to form a coil 106. As shown, at least one, but preferably two spool
terminals 108 extend perpendicularly from the top of the spool 102 such
that they are parallel to a longitudinal axis 110 defined by the coil
assembly. The wire 104 defines two ends 112 and each end 112 of the wire
104 is wrapped around a respective spool terminal 108.
FIG. 5 shows that the coil assembly 100 also includes a connector housing
114 that is mechanically coupled to the spool 102. As shown, the connector
housing 114 forms an internal cavity 116 that is sized and shaped to
receive a male electrical connector leading to and from a vehicle control
system. Moreover, the connector housing 114 includes at least one, but
preferably two connector terminals 118.
It is to be understood that the connector terminals 118 are identical to
each other and that each includes a lower connector terminal portion 120
that extends from within the cavity 116 through the connector housing 114
and beyond the top thereof. As shown, the lower connector terminal portion
120 of each connector terminal 118 is parallel to the longitudinal axis
110 of the coil assembly 100. A lateral connector terminal portion 122
extends perpendicularly from the lower connector terminal portion 120
toward the spool 102. Moreover, an upper connector terminal portion 124
extends perpendicularly from the lateral connector terminal portion 122 in
an upwards direction such that it is parallel to the longitudinal axis
110. It is to be understood that when the connector housing 114 is coupled
to the spool 102, the upper connector terminal portion 124 of each
connector terminal 118 is slightly spaced from a respective spool terminal
108. Accordingly, during assembly, when the spool 102 is coupled to the
connector housing 114 each connector terminal 118 can be preferably
soldered to a respective spool terminal 108.
While the particular SOLENOID COIL ASSEMBLY as herein shown and described
in detail is fully capable of attaining the above-described objects of the
invention, it is to be understood that it is the presently preferred
embodiment of the present invention and thus, is representative of the
subject matter which is broadly contemplated by the present invention,
that the scope of the present invention fully encompasses other
embodiments which may become obvious to those skilled in the art, and that
the scope of the present invention is accordingly to be limited by nothing
other than the appended claims, in which reference to an element in the
singular is not intended to mean "one and only one" unless explicitly so
stated, but rather "one or more." All structural and functional
equivalents to the elements of the above-described preferred embodiment
that are known or later come to be known to those of ordinary skill in the
art are expressly incorporated herein by reference and are intended to be
encompassed by the present claims. Moreover, it is not necessary for a
device or method to address each and every problem sought to be solved by
the present invention, for it is to be encompassed by the present claims.
Furthermore, no element, component, or method step in the present
disclosure is intended to be dedicated to the public regardless of whether
the element, component, or method step is explicitly recited in the
claims. No claim element herein is to be construed under the provisions of
35 U.S.C. section 112, sixth paragraph, unless the element is expressly
recited using the phrase "means for."
*
