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Patent Abstract
A linear solenoid valve includes a solenoid having a coil wound
around a coil bobbin, a fixed core, and a movable core for being
attracted to the fixed core when the coil is energized, and a valve
mechanism having a valve element for selectively bringing an inlet
port and an outlet port into and out of fluid communication with
each other responsive to a displacement of the movable core. The
movable core has a nonmagnetic layer formed on an outer surface
thereof and having a predetermined thickness.
Patent Claims
What is claimed is:
1. A linear solenoid valve for generating an electromagnetic force
in proportion to an amount of current supplied to a solenoid and
displacing a valve element under the generated electromagnetic force,
comprising: a valve casing including a valve body having an inlet
port and an outlet port for passage of a fluid under pressure therethrough,
and a housing joined to said valve body; a solenoid mounted in said
housing and having a coil wound around a coil bobbin, a fixed core,
and a movable core for being attracted to said fixed core when said
coil is energized; and a valve mechanism mounted in said valve body
and having a valve element for selectively bringing said inlet port
and said outlet port into and out of fluid communication with each
other responsive to a displacement of said movable core; said movable
core having a nonmagnetic layer formed on an outer surface thereof
and having a predetermined thickness.
2. A linear solenoid valve according to claim 1, wherein the thickness
of said nonmagnetic layer is in the range from 10 .mu.m to 30 .mu.m.
3. A linear solenoid valve according to claim 1, wherein the thickness
of said nonmagnetic layer is in the range from 50 .mu.m to 100 .mu.m.
4. A linear solenoid valve according to claim 1, wherein said nonmagnetic
layer is formed by a high-frequency induction hardening process
performed on said movable core.
5. A linear solenoid valve according to claim 1, wherein said coil
comprises a wire of square cross section.
6. A linear solenoid valve according to claim 1, wherein said coil
comprises a wire of elongate rectangular cross section.
7. A linear solenoid valve according to claim 1, wherein said solenoid
further comprises a tubular yoke disposed between said movable core
and said coil bobbin, said tubular yoke having a thin-walled annular
guide on an end thereof which faces said fixed core.
8. A linear solenoid valve according to claim 1, wherein said solenoid
further comprises a tubular yoke disposed between said movable core
and said coil bobbin, said tubular yoke has an annular flat surface
on an end thereof which faces said fixed core and lies perpendicular
to the axis of said tubular yoke, and said fixed core has an annular
conical surface on an end thereof which faces said tubular yoke,
said annular conical surface extending on an outer circumferential
surface of said fixed core.
9. A linear solenoid valve for generating an electromagnetic force
in proportion to an amount of current supplied to a solenoid and
displacing a valve element under the generated electromagnetic force,
comprising: a valve casing including a valve body having an inlet
port and an outlet port for passage of a fluid under pressure therethrough,
and a housing joined to said valve body; a solenoid mounted in said
housing and having a coil wound around a coil bobbin, a fixed core,
a movable core for being attracted to said fixed core when said
coil is energized, and a tubular yoke surrounding said movable core;
and a valve mechanism mounted in said valve body and having a valve
element for selectively bringing said inlet port and said outlet
port into and out of fluid communication with each other responsive
to a displacement of said movable core; said movable core having
a nonmagnetic layer formed on an outer surface thereof and having
a predetermined thickness; said coil bobbin having an annular land
formed integrally with an inner wall thereof, said annular land
closing an axial space defined between said tubular yoke and said
fixed core.
10. A linear solenoid valve according to claim 9, wherein the thickness
of said nonmagnetic layer is in the range from 10 .mu.m to 30 .mu.m.
11. A linear solenoid valve according to claim 9, wherein the thickness
of said nonmagnetic layer is in the range from 50 .mu.m to 100 .mu.m.
12. A linear solenoid valve according to claim 9, wherein said
nonmagnetic layer is formed by a high-frequency induction hardening
process performed on said movable core.
13. A linear solenoid valve according to claim 9, wherein said
coil comprises a wire of square cross section.
14. A linear solenoid valve according to claim 9, wherein said
coil comprises a wire of elongate rectangular cross section.
15. A linear solenoid valve according to claim 9, wherein said
tubular yoke is separate from said housing and has an axial end
held by an inner wall of a bottom of said housing.
16. A linear solenoid valve for generating an electromagnetic force
in proportion to an amount of current supplied to a solenoid and
displacing a valve element under the generated electromagnetic force,
comprising: a valve casing including a valve body having an inlet
port and an outlet port for passage of a fluid under pressure therethrough,
and a housing joined to said valve body; a solenoid mounted in said
housing and having a coil wound around a coil bobbin, a fixed core,
a movable core for being attracted to said fixed core when said
coil is energized, and a tubular yoke surrounding said movable core;
and a valve mechanism mounted in said valve body and having a valve
element for selectively bringing said inlet port and said outlet
port into and out of fluid communication with each other responsive
to a displacement of said movable core; said movable core having
a nonmagnetic layer formed on an outer surface thereof and having
a predetermined thickness; said tubular yoke having a thin-walled
annular sleeve lightly press-fitted in a recess defined in said
fixed core.
17. A linear solenoid valve according to claim 16, wherein the
thickness of said nonmagnetic layer is in the range from 10 .mu.m
to 30 .mu.m.
18. A linear solenoid valve according to claim 16, wherein the
thickness of said nonmagnetic layer is in the range from 50 .mu.m
to 100 .mu.m.
19. A linear solenoid valve according to claim 16, wherein said
nonmagnetic layer is formed by a high-frequency induction hardening
process performed on said movable core.
20. A linear solenoid valve according to claim 16, wherein said
coil comprises a wire of square cross section.
21. A linear solenoid valve according to claim 16, wherein said
coil comprises a wire of elongate rectangular cross section.
22. A linear solenoid valve according to claim 16, wherein said
thin-walled annular sleeve projects axially a predetermined distance
from a surface disposed on an end of said tubular yoke and lying
perpendicular to the axis of said tubular yoke.
23. A linear solenoid valve according to claim 16, wherein said
solenoid further includes a plate mounted on an inner wall of a
bottom of said housing, said plate having a raised region held in
abutment against a flat end face of said movable core.
24. A linear solenoid valve according to claim 16, wherein said
movable core has a plurality of inner passages extending parallel
to the axis thereof and extending therethrough between opposite
ends thereof.
25. A linear solenoid valve according to claim 16, wherein said
thin-walled annular sleeve has a thickness of about 0.3 mm.
26. A linear solenoid valve for generating an electromagnetic force
in proportion to an amount of current supplied to a solenoid and
displacing a valve element under the generated electromagnetic force,
comprising: a valve casing including a valve body having an inlet
port and an outlet port for passage of a fluid under pressure therethrough,
and a housing joined to said valve body; a solenoid mounted in said
housing and having a coil wound around a cylindrical pipe made of
a nonmagnetic metal material with an insulating film interposed
therebetween, a fixed core, a movable core for being attracted to
said fixed core when said coil is energized, and a tubular yoke
surrounding said movable core; and a valve mechanism mounted in
said valve body and having a valve element for selectively bringing
said inlet port and said outlet port into and out of fluid communication
with each other responsive to a displacement of said movable core;
said movable core having a nonmagnetic layer formed on an outer
surface thereof and having a predetermined thickness; said tubular
yoke and said fixed core being press-fitted in and held coaxially
with a hole defined in said pipe.
27. A linear solenoid valve according to claim 26, wherein the
thickness of said nonmagnetic layer is in the range from 10 .mu.m
to 30 .mu.m.
28. A linear solenoid valve according to claim 26, wherein the
thickness of said nonmagnetic layer is in the range from 50 .mu.m
to 100 .mu.m.
29. A linear solenoid valve according to claim 26, wherein said
nonmagnetic layer is formed by a high-frequency induction hardening
process performed on said movable core.
30. A linear solenoid valve according to claim 26, wherein said
coil comprises a wire of square cross section.
31. A linear solenoid valve according to claim 26, wherein said
coil comprises a wire of elongate rectangular cross section.
32. A linear solenoid valve according to claim 26, wherein said
fixed core has an annular groove defined in the outer circumferential
surface thereof, said solenoid further including a disk-shaped member
made of a resin material and fitted in said annular groove.
33. A linear solenoid valve according to claim 32, wherein said
pipe has an end held in engagement with said disk-shaped member.
Patent Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a linear solenoid valve
for generating an electromagnetic force in proportion to an amount
of current supplied to a solenoid and displacing a valve element
under the generated electromagnetic force.
[0003] 2. Description of the Related Art
[0004] There have been used in the art electromagnetic valves for
displacing a valve element by attracting a movable core to a fixed
core under an electromagnetic force that is generated when a solenoid
coil is energized.
[0005] Japanese Utility Model Laid-Open Publication No. 63-56371,
for example, discloses a technical idea for coating the entire surface
of a movable core of a solenoid-operated valve with a nonmagnetic,
wear-resistant thin film for suppressing a reduction in the density
of magnetic fluxes produced by a magnetic circuit of the solenoid-operated
valve.
[0006] With the solenoid-operated valve disclosed in Japanese Utility
Model Laid-Open Publication No. 63-56371, however, since the entire
surface of the movable core, which is of a predetermined diameter,
is coated with the thin film, the outside diameter of the movable
core is increased by the thickness of the thin film. Consequently,
it is necessary to manage not only the outside diameter of the movable
core itself, but also the thickness of the applied thin film.
[0007] Furthermore, because the thin film applied to the entire
surface of the movable core may possibly be peeled off or swollen
on the outer surface of the movable core, the disclosed solenoid-operated
valve needs to incorporate some countermeasures for preventing the
thin film from being peeled off or swollen on the outer surface
of the movable core.
[0008] There is a demand for increased coaxial alignment between
a yoke and a fixed core of the solenoid-operated valve for reducing
hysteresis that occurs when the movable core is reciprocally moved.
SUMMARY OF THE INVENTION
[0009] It is a general object of the present invention to provide
a linear solenoid valve which includes a movable core that does
not need to be coated with a nonmagnetic thin film and can produce
a magnetic gap highly accurately.
[0010] Another object of the present invention is to provide a
linear solenoid valve which has a yoke and a fixed core that are
held in desired coaxial alignment with each other.
[0011] The above and other objects, features, and advantages of
the present invention will become more apparent from the following
description when taken in conjunction with the accompanying drawings
in which preferred embodiments of the present invention are shown
by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a longitudinal cross-sectional view of a hydraulic
control valve according to a first embodiment of the present invention,
taken along an axial direction thereof;
[0013] FIG. 2 is a longitudinal cross-sectional view of the hydraulic
control valve, showing a spool valve displaced when a solenoid of
the hydraulic control valve shown,in FIG. 1 is energized;
[0014] FIG. 3 is an enlarged longitudinal cross-sectional view
of a movable core shown in FIG. 1, which has a thin nonmagnetic
layer disposed on an entire outer surface thereof;
[0015] FIG. 4 is an enlarged longitudinal cross-sectional view
of a movable core shown in FIG. 1, which has a thick nonmagnetic
layer disposed on an entire outer surface thereof;
[0016] FIG. 5 is an enlarged fragmentary longitudinal cross-sectional
view of a coil assembly of the hydraulic control valve shown in
FIG. 1;
[0017] FIG. 6 is an enlarged fragmentary longitudinal cross-sectional
view of a coil having a wire of square cross section which is wound
around a coil bobbin;
[0018] FIG. 7 is an enlarged fragmentary longitudinal cross-sectional
view of a coil which is wound around a coil bobbin which is free
of a flange;
[0019] FIG. 8 is an enlarged fragmentary longitudinal cross-sectional
view of a modification of the coil assembly shown in FIG. 5;
[0020] FIG. 9 is an enlarged fragmentary longitudinal cross-sectional
view of a coil having a wire of elongate rectangular cross section
which is wound around a coil bobbin;
[0021] FIG. 10 is an enlarged fragmentary longitudinal cross-sectional
view showing an annular guide disposed on an end of a yoke;
[0022] FIG. 11 is an enlarged fragmentary view showing a magnetic
circuit of the solenoid;
[0023] FIG. 12 is a longitudinal cross-sectional view of a hydraulic
control valve according to a second embodiment of the present invention,
taken along an axial direction thereof;
[0024] FIG. 13 is a longitudinal cross-sectional view of the hydraulic
control valve, showing a spool valve displaced when a solenoid of
the hydraulic control valve shown in FIG. 12 is energized;
[0025] FIG. 14 is an enlarged fragmentary longitudinal cross-sectional
view of a coil assembly of the hydraulic control valve shown in
FIG. 12;
[0026] FIG. 15 is an enlarged fragmentary longitudinal cross-sectional
view of a modification of the coil assembly shown in FIG. 14;
[0027] FIG. 16 is an enlarged fragmentary longitudinal cross-sectional
view showing a radially inward land of a coil bobbin which is disposed
between a yoke and a fixed core;
[0028] FIG. 17 is an enlarged fragmentary view showing a magnetic
circuit of the solenoid;
[0029] FIG. 18 is a longitudinal cross-sectional view of a hydraulic
control valve according to a third embodiment of the present invention,
taken along an axial direction thereof;
[0030] FIG. 19 is a longitudinal cross-sectional view of the hydraulic
control valve, showing a spool valve displaced when a solenoid of
the hydraulic control valve shown in FIG. 18 is energized;
[0031] FIG. 20 is an enlarged longitudinal cross-sectional view
of a movable core shown in FIG. 18, which has a thin nonmagnetic
layer disposed on an entire outer surface thereof;
[0032] FIG. 21 is an enlarged longitudinal cross-sectional view
of a movable core shown in FIG. 18, which has a thick nonmagnetic
layer disposed on an entire outer surface thereof;
[0033] FIG. 22 is an enlarged fragmentary longitudinal cross-sectional
view of a coil assembly of the hydraulic control valve shown in
FIG. 18;
[0034] FIG. 23 is an enlarged fragmentary longitudinal cross-sectional
view of a modification of the coil assembly shown in FIG. 22;
[0035] FIG. 24 is an enlarged fragmentary longitudinal cross-sectional
view showing a thin-walled annular portion of a yoke which is lightly
press-fitted in a recess in a fixed core;
[0036] FIG. 25 is an enlarged fragmentary view showing a magnetic
circuit of the solenoid;
[0037] FIG. 26 is a longitudinal cross-sectional view of a hydraulic
control valve according to a fourth embodiment of the present invention,
taken along an axial direction thereof;
[0038] FIG. 27 is a longitudinal cross-sectional view of the hydraulic
control valve, showing a spool valve displaced when a solenoid of
the hydraulic control valve shown in FIG. 26 is energized;
[0039] FIG. 28 is an enlarged fragmentary longitudinal cross-sectional
view of a coil assembly of the hydraulic control valve shown in
FIG. 26;
[0040] FIG. 29 is an enlarged fragmentary longitudinal cross-sectional
view of a modification of the coil assembly shown in FIG. 28;
[0041] FIG. 30 is an enlarged fragmentary view showing a magnetic
circuit of the solenoid; and
[0042] FIG. 31 is an enlarged fragmentary longitudinal cross-sectional
view of a conventional coil wound around a coil bobbin.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] FIG. 1 shows in longitudinal cross section a hydraulic control
valve 10 according to a first embodiment of the present invention.
[0044] As shown in FIG. 1, the hydraulic control valve 10 comprises
a housing 14 with a solenoid (linear solenoid) 12 disposed therein
and a valve body 18 integrally coupled to the housing 14 and housing
a valve mechanism 16 therein. The housing 14 and the valve body
18 jointly function as a valve casing. The housing 14 is in the
form of a bottomed hollow cylinder made of a magnetic material such
as free-cutting steel including SUM (Japanese Industrial Standard
(JIS)) or the like.
[0045] The housing 14 comprises a hollow cylindrical member 15,
a tubular yoke 22 disposed in and spaced radially inwardly a predetermined
distance from the hollow cylindrical member 15, the yoke 22 extending
substantially parallel to the hollow cylindrical member 15, and
a bottom 17 which is thicker than the hollow cylindrical member
15 and joining the left ends of the hollow cylindrical member 15
and the yoke 22. The hollow cylindrical member 15, the yoke 22,
and the bottom 17 are formed integrally with each other. The bottom
17 has a recess of substantially U-shaped cross section defined
in an inner wall surface thereof, leaving a thin-walled region 19.
[0046] The thin-walled region 19 of the bottom 17, which confronts
an end face of a movable core 26, described later, functions as
a magnetic resistance for minimizing magnetic fluxes flowing through
the thin-walled region 19 of the housing 14.
[0047] As shown in FIGS. 1, 2, and 5, the solenoid 12 includes
a coil assembly 20 disposed in the housing 14, the tubular yoke
22 formed integrally with the housing 14 at the closed end thereof
and disposed in the coil assembly 20, a fixed core 24 joined to
an open end of the housing 14 and axially spaced a predetermined
clearance from the yoke 22 within the coil assembly 20, and a movable
core 26 slidably fitted in the yoke 22 and the fixed core 24.
[0048] The coil assembly 20 comprises a coil bobbin 30 made of
a synthetic resin material and having flanges 28a, 28b disposed
on respective axially spaced ends thereof, and a coil 32 having
a plurality of turns wound around the coil bobbin 30 and comprising
a conductive wire having a square cross section, as shown in FIGS.
5 and 6.
[0049] The coil 32 of square cross section which is wound around
the coil bobbin 30 allows its turns held in surface-to-surface contact
with each other. Therefore, the turns of the coil 32 are stably
arrayed in desired positions. Since the turns of the coil 32 are
thus stably arrayed, one of the flanges 28a or 28b may be dispensed
with as shown in FIG. 7. If one of the flanges 28a, 28b is dispensed
with, the axial dimension of the solenoid 12 is reduced to make
the solenoid 12 smaller in size.
[0050] If a conventional coil comprising a conductive wire of circular
cross section is wound around a coil bobbin, as shown in FIG. 31,
then the coil is subject to forces tending to cause the coil to
collapse toward a flange under the tension of the wound coil. The
coil 32 of square cross section according to the present embodiment
has its turns held in surface-to-surface contact with each other
and is not subject to forces tending to cause the coil 32 to collapse
toward the flange 28a, 28b. Consequently, one of the flanges 28a
or 28b may be dispensed with.
[0051] As shown in FIGS. 8 and 9, the solenoid 12 may have a coil
32a comprising a flat conductive wire of elongate rectangular cross
section. However, the coil 32 of square cross section can be wound
in a smaller space than the coil 32a of elongate rectangular cross
section. Furthermore, since the coil 32 of square cross section
has a smaller cross-sectional circumferential dimension than the
coil 32a of elongate rectangular cross section, the cross-sectional
area of an insulating film on the coil 32 may be set to a small
value.
[0052] As shown in FIG. 5, the yoke 22 has an annular flat surface
34 on the right end thereof which faces the fixed core 24, and the
fixed core 24 has an annular conical surface 38 on the left end
thereof which faces the yoke 22. The annular flat surface 34 lies
perpendicularly to the axis of the yoke 22, and the annular conical
surface 38 extends on the outer circumferential surface of the fixed
core 24 around a recess 36 defined in the fixed core 24. The yoke
22 also has a tapered surface 35 formed on an end face thereof adjacent
to the annular flat surface 34 as a circumferentially beveled surface
for reducing a flux leakage.
[0053] The tubular yoke 22 and the recess 36 defined in the fixed
core 24 are complementary in shape to the movable core 26, providing
a linear solenoid structure in which the movable core 26 is slidable
between the tubular yoke 22 and the recess 36 defined in the fixed
core 24.
[0054] As shown in FIG. 10, a thin-walled annular guide 39 projecting
a predetermined distance toward the conical surface 38 of the fixed
core 24 may be disposed on the flat surface 34 of the yoke 22 which
axially confronts the conical surface 38 of the fixed core 24.
[0055] In the structure shown in FIG. 10, a gap 41 is present as
a clearance between the annular guide 39 and the conical surface
38 of the fixed core 24. The thin-walled annular guide 39 on the
yoke 22 is effective to guide the movable core 26 stably for better
linear movement with respect to the fixed core 24.
[0056] As shown in FIG. 5, a synthetic resin sealing body 40 which
is molded over the outer circumferential surface of the coil 32
and a portion of the coil bobbin 30 is disposed between the housing
14 and the coil 32. The synthetic resin sealing body 40 is molded
of a synthetic resin material integrally with a coupler 42. The
coupler 42 has a terminal 44 electrically connected to the coil
32 and having an exposed terminal end 44a that is electrically connected
to a power supply (see FIGS. 1 and 2).
[0057] The coil 32 has its outer circumferential surface covered
with the synthetic resin sealing body 40 for being stably protected.
If one of the flanges 28a (28b) on the ends of the coil bobbin 30
is dispensed with, then the portion of the coil bobbin 30 which
lacks the flange 28a (28b) is also covered with the synthetic resin
sealing body 40 for protecting the coil 32 more stably.
[0058] As shown in FIGS. 1 and 2, the movable core 26 comprises
a cylindrical movable core body 45, an boss 47 formed integrally
with the central region of an end of the movable core body 45 and
projecting a predetermined distance toward the fixed core 24, and
a protrusion 53 formed integrally with the central region of the
opposite end of the movable core body 45 and projecting a predetermined
distance toward the thin-walled region 19 of the housing 14.
[0059] A ring 52 is mounted on the outer circumferential surface
of the boss 47. The ring 52 is made of a nonmagnetic material and
functions as a spacer for preventing residual magnetism from being
produced in the solenoid 12.
[0060] Specifically, when the solenoid 12 is de-energized, residual
magnetism may be produced in the fixed core 24 or the movable core
26, tending to keep the movable core 26 attracted to the fixed core
24. However, the nonmagnetic ring 52 disposed on the end face of
the movable core 26 and mounted on the boss 47 forms a certain clearance
between the movable core 26 and the fixed core 24, thereby preventing
residual magnetism from being produced.
[0061] The protrusion 53 projects integrally axially from the center
of the other end of the movable core body 45. The protrusion 53
functions as a stopper for abutment against the thin-walled region
19 of the bottom 17 of the housing 14. The protrusion 53 is formed
as part of a nonmagnetic layer 65 (described below), and functions
as a spacer for preventing residual magnetism from being produced
in the solenoid 12. The movable core body 45 has axial communication
grooves 54 defined in its outer circumferential surface and providing
communication between the opposite ends of the movable core body
45.
[0062] The movable core 26 has the nonmagnetic layer 65 on its
entire outer surface, the nonmagnetic layer 65 having a predetermined
depth (see FIGS. 3 and 4).
[0063] The nonmagnetic layer 65 of the movable core 26 is formed
by a surface reforming process such as a carburizing process and/or
a nitriding process. The carburizing process and the nitriding process
are advantageous in that they prevent the movable core 26 from changing
dimensions and make any subsequent processes unnecessary because
they can improve the magnetic permeability of the movable core 26
at a relatively low temperature.
[0064] The carburizing process may be a solid carburizing process,
a liquid carburizing process (carbonitriding process), a gas carburizing
process, a plasma carburizing process, or the like. The nitriding
process may be a gas nitriding process, a liquid nitriding process
(salt bath nitriding process), a soft nitriding process, an ion
nitriding process, or the like.
[0065] Alternatively, the nonmagnetic layer 65 may be formed on
the outer surface of the movable core 26 by a high-frequency induction
hardening process, for example. If the nonmagnetic layer 65 is formed
by a high-frequency induction hardening process, then the movable
core 26 can be heat-treated at a high speed, and hence can be produced
in a shortened manufacturing process. The process of forming the
nonmagnetic layer 65 on the outer surface of the movable core 26
is not limited to the surface reforming process such as the carburizing
process, the nitriding process, or the high-frequency induction
hardening process. The nonmagnetic layer 65 may be formed on the
outer surface of the movable core 26 by another surface reforming
process such as a laser beam applying process.
[0066] The movable core 26 may be made of ferrite-base stainless
steel such as SUS410L, SUS405 (JIS), or the like, general steel
such as S10C (JIS) or the like, or free cutting steel such as SUM
(JIS) or the like.
[0067] As shown in FIG. 3, if the nonmagnetic layer 65 formed on
the outer surface of the movable core 26 is a thin layer, then the
thickness T1 of the nonmagnetic layer 65 may be in the range from
10 .mu.m to 30 .mu.m, or preferably 20 .mu.m. With the thin nonmagnetic
layer 65, the magnetic gap produced between the movable core 26
and the yoke 22 can be greatly reduced for increased magnetic forces
and hence large attractive force. Therefore, according to the first
embodiment, the movable core 26 may be smaller in size than a movable
core which is cable of producing the same attractive forces.
[0068] As shown in FIG. 4, if the nonmagnetic layer 65 formed on
the outer surface of the movable core 26 is a thick layer, then
the thickness T2 of the nonmagnetic layer 65 may be in the range
from 50 .mu.m to 100 .mu.m, or preferably 75 .mu.m. With the thick
nonmagnetic layer 65, the magnetic gap produced between the movable
core 26 and the yoke 22 can be increased for suppressing side forces
acting between the movable core 26 and the yoke 22. If the movable
core 26 with the thick nonmagnetic layer 65 is incorporated in a
linear solenoid whose hysteresis increases with the side forces,
then the linear solenoid has low hysteresis.
[0069] The magnetic material which the movable core 26 is made
of may contain 12 weight % or less of Cr for increased durability.
[0070] As shown in FIGS. 3 and 4, the boss 47 and the protrusion
53 are formed integrally with the movable core body 45. However,
a shaft (not shown) separate from the movable core body 45 may be
fitted in a through hole (not shown) defined axially in the movable
core body 45, and the shaft may have an end projecting a predetermined
distance from an end face of the movable core body 45, providing
the boss 47, with the other end of the shaft projecting a predetermined
distance from the other end face of the movable core body 45, providing
the protrusion 53.
[0071] The fixed core 24 has a through hole 50 defined centrally
axially therethrough, with a shaft 46 of a spool valve 66 (described
later) extending through the through hole 50.
[0072] The valve mechanism 16 has the valve body 18 having an inlet
port 56, an outlet port 58, a drain port 60, and a breather port
62 communicating with an oil tank (not shown), defined in a side
wall thereof, and a spool valve (valve element) 66 axially displaceably
disposed in a space 64 defined in the valve body 18.
[0073] The spool valve 66 has a first land 66a, a second land 66b,
and a third land 66c which are positioned successively from the
solenoid 12. The first land 66a and the second land 66b are of the
same diameter, and the third land 66c is slightly smaller in diameter
than the first land 66a and the second land 66b.
[0074] The space 64 in the valve body 18 is closed by an end block
68 disposed in the end of the valve body 18 remote from the solenoid
12. A return spring 70 for normally pressing the spool valve 66
toward the solenoid 12 is disposed between the end block 68 and
the spool valve 66. The return spring 70 is illustrated as being
a helical spring. However, the return spring 70 is not limited to
a helical spring, but may be another resilient member such as a
leaf spring or the like.
[0075] The spool valve 66 integrally has a shaft 46 on an end thereof
facing the solenoid 12 and held in abutting engagement with the
end face of the boss 47 of the movable core 26. The spring force
of the return spring 70 acts through the spool valve 66 and the
shaft 46 on the movable core 26, pressing the movable core 26 axially
in the direction indicated by the arrow X1 in FIG. 1.
[0076] The hydraulic control valve 10 according to the first embodiment
is basically constructed as described above. Operation and advantages
of the hydraulic control valve 10 will be described below.
[0077] When the solenoid 12 is de-energized, the spool valve 66
is pressed axially in the direction indicated by the arrow X1 in
FIG. 1 under the spring force (pressing force) of the return spring
70, holding the inlet port 56 and the outlet port 58 out of communication
with each other.
[0078] When the non-illustrated power supply is turned on, the
coil 32 of the solenoid 12 is energized, causing a magnetic circuit
82 as shown in FIG. 11 to generate an electromagnetic force. At
this time, the generated electromagnetic force is proportional to
the amount of current supplied to the coil 32, and is applied to
the movable core 26. Under the generated electromagnetic force,
the shaft 46 and hence the spool valve 66 are axially displaced
in the direction indicated by the arrow X2 in FIG. 1 against the
bias of the return spring 70. The drain port 60 and the outlet port
58 are brought out of communication with each other, and the inlet
port 56 and the outlet port 58 are brought into communication with
each other (see FIG. 2).
[0079] Oil which is supplied under pressure from an oil source
(not shown) through a passageway (not shown) flows through the inlet
port 56 and the outlet port 58 and is supplied to a hydraulic device
(not shown). When the solenoid 12 is de-energized, the spool valve
66 returns to the initial position shown in FIG. 1 under the bias
of the return spring 70.
[0080] In the first embodiment, since the nonmagnetic layer 65
is formed on the entire outer surface of the movable core 26 by
the surface reforming process, the nonmagnetic layer 65 functions
as a magnetic gap in the magnetic circuit 82 that is made when the
coil 32 is energized.
[0081] As the nonmagnetic layer 65 is formed on the entire outer
surface of the movable core 26, the movable core 26 can easily be
formed to desired dimensions by simply managing the outside diameter
of the movable core 26. Therefore, a magnetic gap provided by the
clearance between the yoke 22 and the movable core 26 can be managed
with accuracy for better magnetic characteristics.
[0082] Because of the nonmagnetic layer 65 formed on the entire
outer surface of the movable core 26, the movable core 26 is prevented
from sticking to the inner wall surface of the yoke 22. In addition,
the hydraulic control valve 10 is not required to have a separate
nonmagnetic thin film or member, e.g., a nonmagnetic pipe, which
would otherwise be used between the movable core 26 and the yoke
22.
[0083] Since such a separate nonmagnetic thin film is not necessary,
there is no need to manage the thickness of the nonmagnetic thin
film which would otherwise tend to affect the outside diameter of
the movable core 26. The nonmagnetic layer 65 is not liable to be
peeled off, swell, and cause surface irregularities and pinholes,
making the movable core 26 high in durability and good in quality.
[0084] The nonmagnetic layer 65 formed on the entire outer surface
of the movable core 26 may be made thin or thick for adjusting the
size of the magnetic gap (the clearance between the outer circumferential
surface of the movable core 26 and the inner wall surface of the
yoke 22). As a result, it is possible to produce desired attractive
forces depending on the size of the magnetic gap. If the magnetic
gap is minimized insofar as the slidability between the movable
core 26 and the yoke 22 is maintained, then the movable core 26
is prevented from being tilted as it is. displaced toward the fixed
core 24, resulting in stable magnetic characteristics.
[0085] In the first embodiment, furthermore, the coil 32 wound
around the coil bobbin 30 of the solenoid 12 is of square cross
section, thereby minimizing any gaps between stacked turns of the
coil 32. Therefore, the total cross-sectional area of the coil 32,
i.e., the overall space occupied by the coil 32 wound around the
coil bobbin 30, is smaller than that of the conventional solenoid
coil of circular cross section which has the same number of turns
as the coil 32.
[0086] Stated otherwise, the ratio of the cross-sectional area
of the conductor of the coil 32 to the space in which the coil 32
is wound, i.e., the conductor occupation ratio, may be greater than
that of the solenoid coil of circular cross section.
[0087] Since the space in which the coil 32 is wound can be reduced,
the coil bobbin 30 can be reduced in size, resulting in a reduction
in the overall size of the solenoid 12.
[0088] If the space in which the coil 32 is wound is the same as
the space in which the solenoid coil of circular cross section is
wound, then the number of turns of the coil 32 of square cross section
on the coil bobbin 30 is greater than that of the solenoid coil
of circular cross section. Accordingly, the solenoid 12 can produce
greater attractive forces (electromagnetic forces) than the solenoid
coil of circular cross section.
[0089] In the first embodiment, since the space in which the coil
32 is wound can be reduced, the total dimension (total length) of
the continuous wire of the coil 32 can be reduced, and hence the
resistance of the coil 32 can be reduced. As a result, the electric
power consumed when the coil 32 is energized can be reduced.
[0090] If the coil 32 of square cross section has the same resistance
as the solenoid coil of circular cross section, then the number
of turns of the coil 32 wound around the coil bobbin 30 is increased
in the first embodiment for producing increased attractive forces
(electromagnetic forces).
[0091] In the first embodiment, inasmuch as the coil 32 of square
cross section has its turns held in surface-to-surface contact with
each other, the conductor occupation ratio in the space in which
the coil 32 is wound is greater than the conductor occupation ratio
in the space in which the coil of circular cross section is wound.
[0092] Consequently, any gaps between stacked turns of the coil
32 can be minimized for increasing the density of turns of the coil
32 per unit volume in the space in which the coil 32 is wound. As
a result, the heat transfer capability (heat radiation capability)
in the space in which the coil 32 is wound is increased. If the
present invention is applied to an electromagnetic valve for use
in an environment where the atmospheric temperature is lower than
the temperature to which the coil is heated, then since the heat
radiation capability can be increased and the resistance of the
coil 32 can be reduced, the amount of heat generated by the coil
32 when it is energized is reduced. Therefore, the resistance of
the coil 32 can further be reduced.
[0093] The solenoid 12 including the coil 32 of square cross section
can be used in an electromagnetic valve for use on vehicles. Generally,
there is a minimum battery voltage of 8 V, for example, to be applied
to electric parts for use on vehicles. Since electromagnetic valves
for use on vehicles are required to maintain a minimum magnetomotive
force (current value), the maximum resistance that the electromagnetic
valves should have are necessarily determined if the same magnetic
circuit is employed. Because the resistance of the coil 32 generally
increases as the temperature thereof increases, the maximum resistance
has to be of a value taking into account the temperature-dependent
resistance increase. If the maximum resistance is set without taking
into account the temperature-dependent resistance increase, then
the electromagnetic valve may not have a required current and may
not possibly obtain a minimum magnetomotive force. Therefore, if
the solenoid 12 is used in an electromagnetic valve for use on vehicles,
then it is required to maintain a desired magnetomotive force (current
value) though the resistance of the coil 32 increases due to an
increase in the temperature of coil 32 when the solenoid 12 is energized.
[0094] If the resistance of the coil 32 itself and the resistance
of the coil 32 when it is heated upon energization are low, then
they are highly advantageous because the coil 32 can maintain a
high current value according to the Ohm's law. With the coil 32
being of square cross section, if the solenoid 12 can produce the
same magnetomotive force as conventional solenoids, then the resistance
of coil 32 is made smaller and the coil 32 consumes a lower amount
of electric power, which reduces the amount of heat generated by
the coil 32 when it is energized, resulting in a reduction in the
resistance of the coil 32 at the time it is energized and heated.
[0095] As a result, the resistance of the coil 32 at the time it
is energized and heated can be reduced to allow an increased current
to pass through the coil 32. Therefore, the solenoid 12 can appropriately
be used in an electromagnetic valve for which a minimum applied
voltage is limited. Furthermore, since the current value of the
solenoid 12 having the coil 32 of square cross section is made higher
than that of the conventional solenoid having the coil of circular
cross section and producing the same minimum magnetomotive force,
the number of turns of the coil 32 around the coil bobbin 30 is
made smaller, and hence the coil 32 is made smaller in size.
[0096] In the first embodiment, the protrusion 53 which functions
as a stopper is disposed on the end face of the movable core 26
which faces the thin-walled region 19 of the housing 14. The protrusion
53 can also function as a spacer (so-called magnet killer) for preventing
residual magnetism from being generated in the solenoid 12.
[0097] Specifically, magnetic fluxes are less liable to flow into
the thin-walled region 19 of the housing 14, and less liable to
flow into the central area of the thin-walled region 19. With the
protrusion 53 being disposed centrally on the end face of the movable
core 26 which faces the center of the thin-wall region 19, magnetic
fluxes are prevented from flowing into the protrusion 53.
[0098] The protrusion 53 on the end face of the movable core 26
allows a curved edge 72 (see FIG. 5) to be formed on the inner wall
at the bottom of the housing 14 which is engaged by the protrusion
53. Because of the curved edge 72, the housing 14 can be manufactured
with ease.
[0099] The end face of the movable core 26 which has the protrusion
53 thereon faces the wall surface of the thin-walled region 19 with
the protrusion 53 interposed therebetween. Therefore, magnetic fluxes
are prevented from flowing from the thin-walled region 19 of the
housing 14 into the end face of the movable core 26.
[0100] In the first embodiment, furthermore, the outer circumferential
surface of the end of the movable core 26 is disposed between the
bottom 17 of the housing 14 and the tubular yoke 22 at a position
which corresponds to the inner wall surface of the bottom 17 of
the housing 14 (see an encircled portion A in FIG. 5). Therefore,
magnetic fluxes that run from the bottom 17 of the housing 14 to
the movable core 26 are also transferred between the inner wall
surface of the bottom 17 and the outer circumferential surface of
the movable core 26 (see FIG. 11). Therefore, magnetic fluxes are
smoothly transferred between the bottom 17 of the housing 14 and
the end of the movable core 26, so that an increased amount of magnetic
fluxes can be generated by the magnetic circuit.
[0101] As a result, the solenoid 12 can produce increased attractive
forces. If the solenoid 12 is to produce the same attractive forces
as a conventional solenoid, then the hydraulic control valve 10
according to the first embodiment can be reduced in overall size.
[0102] A hydraulic control valve 110 according to a second embodiment
of the present invention is shown in FIGS. 12 through 17. Those
parts of the hydraulic control valve 110 according to the second
embodiment which are identical to those of the hydraulic control
valve 10 according to the first embodiment are denoted by identical
reference characters, and will not be described in detail below.
[0103] The hydraulic control valve 110 according to the second
embodiment has a solenoid 12 including a coil assembly 20 disposed
in a housing 14, a tubular yoke 122 disposed in the coil assembly
20 and extending parallel to a hollow cylindrical member 15 of the
housing 14, a fixed core 24 joined to an open end of the housing
14 and axially spaced a predetermined clearance from the yoke 122
within the coil assembly 20, and a movable core 26 slidably fitted
in the yoke 22 and the fixed core 24.
[0104] The yoke 122 is different from the yoke 22 of the hydraulic
control valve 10 according to the first embodiment in that the yoke
122 comprises a substantially tubular member separate from the housing
14 and has an axial end press-fitted in and held by an inner wall
in a bottom 17 of the housing 14.
[0105] The yoke 122 has an annular flat surface 34 on the right
end thereof which faces the fixed core 24, and the fixed core 24
has an annular conical surface 38 on the left end thereof which
faces the yoke 122. The annular flat surface 34 lies perpendicularly
to the axis of the yoke 22, and the annular conical surface 38 extends
on the outer circumferential surface of the fixed core 24 around
a recess 36 defined in the fixed core 24. The yoke 122 also has
a tapered surface 35 formed on an end face thereof adjacent to the
annular flat surface 34 as a circumferentially beveled surface for
reducing a flux leakage.
[0106] The tubular yoke 122 and the recess 36 defined in the fixed
core 24 are complementary in shape to the movable core 26, providing
a linear solenoid structure in which the movable core 26 is slidable
between tubular yoke 122 and the recess 36 defined in the fixed
core 24.
[0107] As shown in FIG. 16, a coil bobbin 30 has a radially inward
land (annular land) 137 disposed between the yoke 122 and the fixed
core 24. The radially inward land 137 is formed integrally with
the coil bobbin 30 and projects a predetermined distance radially
inwardly of the coil bobbin 30. Stated otherwise, the axial space
between the yoke 122 and the fixed core 24 is closed by the radially
inward land 137 that is formed integrally with the coil bobbin 30.
[0108] The radially inward land 137 is shaped complementarily to
the flat surface 34 of the yoke 122 and the conical surface 38 of
the fixed core 24, providing a guide 141 surrounding the outer circumferential
surface of the movable core 26 with a predetermined clearance interposed
therebetween.
[0109] The coil bobbin 30 with the integrally formed radially inward
land 137 keeps the yoke 122 and the fixed core 24 highly accurately
in coaxial alignment with each other, and allows the yoke 122 and
the fixed core 24 to be assembled with greater ease. Specifically,
the yoke 122 and the fixed core 24 are held by the inner circumferential
surface of the coil bobbin 30, and are held highly accurately in
coaxial alignment with each other by the radially inward land 137
which is disposed in the space across which the yoke 122 and the
fixed core 24 confront each other.
[0110] Since the yoke 122 and the fixed core 24 are kept highly
accurately in coaxial alignment with each other, the movable core
26 can smoothly move reciprocally along the inner wall surface of
the yoke 122 or the inner circumferential surface of the recess
36 in the fixed core 24, and side forces acting on the movable core
26 are reduced to allow the movable core 26 to move reciprocally
smoothly. Therefore, hysteresis is reduced when the movable core
26 moves reciprocally, and the solenoid 12 has good hysteresis characteristics.
[0111] The guide 141 disposed around the outer circumferential
surface of the movable core 26 with the predetermined clearance
interposed therebetween is effective to guide the movable core 26
well for better linear movement.
[0112] The hydraulic control valve 110 according to the second
embodiment is basically constructed as described above. Only operational
details and advantages of the hydraulic control valve 110 which
are different from those of the hydraulic control valve 10 according
to the first embodiment will be described below.
[0113] According to the second embodiment, the radially inward
land 137 which is formed integrally with the coil bobbin 30 and
projecting the predetermined distance radially inwardly of the coil
bobbin 30 is disposed between the yoke 122 and the fixed core 24
(see FIG. 16). The coil bobbin 30 with the integrally formed radially
inward land 137 keeps the yoke 122 and the fixed core 24 highly
accurately in coaxial alignment with each other, and allows the
yoke 122 and the fixed core 24 to be assembled with greater ease.
[0114] Specifically, the yoke 122 and the fixed core 24 are held
by the inner circumferential surface of the coil bobbin 30, and
the radially inward land 137 is disposed in the space across which
the yoke 122 and the fixed core 24 confront each other. This structure
provides highly accurate coaxial alignment between the yoke 122
and the fixed core 24.
[0115] Inasmuch as highly accurate coaxial alignment is maintained
between the yoke 122 and the fixed core 24, the movable core 26
can smoothly move reciprocally along the inner wall surface of the
yoke 122 or the inner circumferential surface of the recess 36 in
the fixed core 24, and side forces acting on the movable core 26
are reduced to allow the movable core 26 to move reciprocally smoothly.
Therefore, hysteresis is reduced when the movable core 26 moves
reciprocally, and the solenoid 12 has good hysteresis characteristics.
[0116] Furthermore, the guide 141 disposed around the outer circumferential
surface of the movable core 26 with the predetermined clearance
interposed therebetween is effective to guide the movable core 26
well for better linear movement.
[0117] In the second embodiment, in addition, the outer circumferential
surface of the end of the movable core 26 is disposed between the
bottom 17 of the housing 14 and the tubular yoke 122 at a position
which corresponds to the inner wall surface of the bottom 17 of
the housing 14 (see an encircled portion B in FIG. 14). Therefore,
magnetic fluxes that run from the bottom 17 of the housing 14 to
the movable core 26 are also transferred between the inner wall
surface of the bottom 17 and the outer circumferential surface of
the movable core 26 (see FIG. 17). Therefore, magnetic fluxes are
smoothly transferred between the bottom 17 of the housing 14 and
the end of the movable core 26, so that an increased amount of magnetic
fluxes can be generated by the magnetic circuit.
[0118] As a result, the solenoid 12 can produce increased attractive
forces. If the solenoid 12 is to produce the same attractive forces
as a conventional solenoid, then the hydraulic control valve 110
according to the second embodiment can be reduced in overall size.
[0119] A hydraulic control valve 210 according to a third embodiment
of the present invention is shown in FIGS. 18 through 25.
[0120] The hydraulic control valve 210 according to the third embodiment
has a solenoid 12 including a coil assembly 20 disposed in a housing
14, a tubular yoke 222 disposed in the coil assembly 20 and extending
parallel to a hollow cylindrical member 15 of the housing 14, a
fixed core 24 joined to an open end of the housing 14 and axially
spaced a predetermined clearance from the yoke 222 within the coil
assembly 20, and a movable core 226 slidably fitted in the yoke
222 and the fixed core 24.
[0121] As shown in FIGS. 22 through 24, the yoke 222 comprises
a substantially tubular member separate from the housing 14 and
has an axial end press-fitted in and held by an inner wall in a
bottom 17 of the housing 14. The yoke 222 has a thin-walled annular
sleeve 227 axially projecting a predetermined distance toward the
fixed core 24.
[0122] The tubular yoke 222 and the recess 36 defined in the fixed
core 24 are complementary in shape to the movable core 226, providing
a linear solenoid structure in which the movable core 226 is slidable
between the tubular yoke 222 and the recess 36 defined in the fixed
core 24.
[0123] As shown in FIG. 24, the thin-walled annular sleeve 227
which axially projects from the flat surface 34 on the end of the
tubular yoke 222 by the predetermined distance is axially disposed
between the yoke 222 and the fixed core 24. The thin-walled annular
sleeve 227 is lightly press-fitted in the recess 36 and joined to
the inner wall surface of the fixed core 24 which defines the recess
36. The thin-walled annular sleeve 227 thus keeps the yoke 222 and
the fixed core 24 highly accurately in coaxial alignment with each
other, and allows the yoke 222 and the fixed core 24 to be assembled
with greater ease.
[0124] Specifically, the fixed core 24 with a conical surface 38
on its outer circumference and the tubular yoke 222 are separate
from each other, and the thin-walled annular sleeve 227 that is
formed integrally with the end of the yoke 222 is lightly press-fitted
into the recess 36 along the inner circumferential surface of the
recess 36, holding the yoke 222 and the fixed core 24 highly accurately
in coaxial alignment with each other.
[0125] Since the yoke 222 and the fixed core 24 are kept highly
accurately in coaxial alignment with each other, the movable core
226 can smoothly move reciprocally along the inner wall surface
of the yoke 222 or the fixed core 24, and side forces acting on
the movable core 226 are reduced to allow the movable core 226 to
move reciprocally smoothly. Therefore, hysteresis is reduced when
the movable core 226 moves reciprocally, and the solenoid 12 has
good hysteresis characteristics.
[0126] The thin-walled annular sleeve 227 has an inner circumferential
surface functioning as a guide surface surrounding the outer circumferential
surface of the movable core 226 with a predetermined clearance interposed
therebetween, for thereby guiding the movable core 226 well for
better linear movement.
[0127] The thin-walled annular sleeve 227 that joins the yoke 222
and the fixed core 24 to each other is of a very small thickness
such as of about 0.3 mm, for example. The thin-walled annular sleeve
227 thus has a reduced magnetic path area and functions as a magnetic
resistance for reducing magnetic fluxes flowing directly between
the yoke 222 and the fixed core 24.
[0128] Furthermore, even though the two members, i.e., the yoke
222 with the thin-walled annular sleeve 227 and the fixed core 24,
are assembled together, they achieve a predetermined mechanical
strength. The assembly of the yoke 222 and the fixed core 24 which
are joined by the thin-walled annular sleeve 227 is made up of a
greater number of parts, but can be manufactured more easily, than
if the yoke, the fixed core, and the thin-walled annular sleeve
were integrally combined with each other, i.e., if they were constructed
as a single structure.
[0129] The movable core 226 comprises a cylindrical movable core
body 245, and a boss 47 formed integrally with the central region
of an end of the movable core body 245 and projecting slightly toward
the fixed core 24. The other end of the movable core 226 which faces
a thin-walled region 19 of the housing 14 is formed as a flat surface.
[0130] A ring 52 is mounted on the outer circumferential surface
of the boss 47. The ring 52 is made of a nonmagnetic material and
functions as a spacer for preventing residual magnetism from being
produced in the solenoid 12.
[0131] The other end of the movable core body 245 is disposed for
abutment against a raised region 253a of a plate 253 which is mounted
on the inner wall of the bottom 17 of the housing 14. The plate
253 is made of a nonmagnetic material and functions as a spacer
for preventing residual magnetism from being produced in the solenoid
12, as with the ring 52.
[0132] The movable core body 245 has a plurality of inner passages
255 extending parallel to the axis thereof and provided by holes
defined therethrough between the opposite ends thereof. The inner
passages 255 has a function to increase the magnetic path area for
passing magnetic fluxes therethrough and also to pass oil under
pressure remaining in the space between the thin-wall region 19
of the housing 14 through the inner passages 255 toward the fixed
core 24, allowing the movable core 226 to return quickly, when the
movable core 226 is displaced toward the thin-wall region 19.
[0133] The movable core 226 has a nonmagnetic layer 65 on its entire
outer surface, the nonmagnetic layer 65 having a predetermined depth
(see FIGS. 20 and 21).
[0134] In the third embodiment, the thin-walled annular sleeve
227 disposed on the end of the yoke 222 is lightly press-fitted
along the inner circumferential surface of the recess 36 in the
fixed core 24, thereby integrally assembling the yoke 222 and the
fixed core 24 together (see FIG. 24). The yoke 222 with the thin-walled
annular sleeve 227 keeps the yoke 222 and the fixed core 24 highly
accurately in coaxial alignment with each other, and allows the
yoke 222 and the fixed core 24 to be assembled with greater ease.
[0135] Since the yoke 222 and the fixed core 24 are kept highly
accurately in coaxial alignment with each other by the thin-walled
annular sleeve 227, the movable core 226 can smoothly move reciprocally
along the yoke 222 or the fixed core 24, and side forces acting
on the movable core 226 are reduced to allow the movable core 226
to move reciprocally smoothly. Therefore, hysteresis is reduced
when the movable core 226 moves reciprocally, and the solenoid 12
has good hysteresis characteristics.
[0136] The thin-walled annular sleeve 227 has an inner circumferential
surface functioning as a guide surface surrounding the outer circumferential
surface of the movable core 226 with a predetermined clearance interposed
therebetween, for thereby guiding the movable core 226 well for
better linear movement.
[0137] The thin-walled annular sleeve 227 that joins the yoke 222
and the fixed core 24 to each other is of a very small thickness
such as of about 0.3 mm, for example. The thin-walled annular sleeve
227 thus has a reduced magnetic path area and functions as a magnetic
resistance for reducing magnetic fluxes flowing directly between
the yoke 222 and the fixed core 24.
[0138] In the third embodiment, in addition, the outer circumferential
surface of the end of the movable core 226 is disposed at a position
which corresponds to the inner wall surface of the bottom 17 of
the housing 14 (see an encircled portion C in FIG. 22). Therefore,
magnetic fluxes that run from the bottom 17 of the housing 14 to
the movable core 226 are also transferred between the inner wall
surface of the bottom 17 and the outer circumferential surface of
the movable core 226 (see FIG. 25). Therefore, magnetic fluxes are
smoothly transferred between the bottom 17 of the housing 14 and
the end of the movable core 226, so that an increased amount of
magnetic fluxes can be generated by the magnetic circuit.
[0139] As a result, the solenoid 12 can produce increased attractive
forces. If the solenoid 12 is to produce the same attractive forces
as a conventional solenoid, then the hydraulic control valve 210
according to the third embodiment can be reduced in overall size.
[0140] A hydraulic control valve 310 according to a fourth embodiment
of the present invention is shown in FIGS. 26 through 30.
[0141] The hydraulic control valve 310 according to the fourth
embodiment has a coil assembly 320 disposed in a housing 14. The
coil assembly 320 comprises a pipe 330 in the form of an elongate
hollow cylindrical member made of a nonmagnetic metal material such
as stainless steel or the like and having uniform diameters (inside
and outside diameters) in the axial direction, and a coil 32 having
a plurality of turns wound around the pipe 330 and comprising a
conductive wire having a square cross section, as shown in FIGS.
26 through 28.
[0142] The pipe 330 on which the coil 32 is wound has an outer
surface coated with an insulating film 331, as shown in FIG. 28.
Since the coil 32 is wound around the pipe 330, a coil bobbin made
of a resin material which has heretofore been employed is dispensed
with.
[0143] The coil 32 of square cross section which is wound around
the pipe 330 allows its turns held in surface-to-surface contact
with each other. Therefore, the turns of the coil 32 are stably
arrayed in desired positions. Since the turns of the coil 32 are
thus stably arrayed, one of the flanges on the axially spaced ends
of the pipe 330 may be dispensed. If one of the flanges is dispensed
with, the axial dimension of the solenoid 12 is reduced to make
the solenoid 12 smaller in size.
[0144] If a conventional coil comprising a conductive wire of circular
cross section is wound around a coil bobbin, as shown in FIG. 31,
then the coil is subject to forces tending to cause the coil to
collapse toward a flange under the tension of the wound coil. The
coil 32 of square cross section has its turns held in surface-to-surface
contact with each other and is not subject to forces tending to
cause the coil 32 to collapse toward the ends of the pipe 330. Consequently,
one of the flanges may be dispensed with.
[0145] As shown in FIG. 29, the solenoid 12 may have a coil 32a
comprising a flat conductive wire of elongate rectangular cross
section. However, the coil 32 of square cross section can be wound
in a smaller space than the coil 32a of elongate rectangular cross
section. Furthermore, since the coil 32 of square cross section
has a smaller cross-sectional circumferential dimension than the
coil 32a of elongate rectangular cross section, the cross-sectional
area of an insulating film on the coil 32 may be set to a small
value.
[0146] The tubular yoke 22 and the recess 36 defined in the fixed
core 24 are complementary in shape to the movable core 26, providing
a linear solenoid structure in which the movable core 26.is slidable
between the tubular yoke 22 and the recess 36 defined in the fixed
core 24.
[0147] As shown in FIG. 26, the yoke 22 and the fixed core 24 are
press-fitted in a hole 333 in the pipe 330 which is integrally formed
of a nonmagnetic metal material, and are kept coaxially spaced a
predetermined distance from each other.
[0148] Specifically, the pipe 330 surrounding and holding the outer
circumferential surface of the yoke 22 and the outer circumferential
surface of the fixed core 24 keeps the yoke 22 and the fixed core
24 highly accurately in coaxial alignment with each other, and allows
the yoke 22 and the fixed core 24 to be assembled with greater ease.
[0149] Since the yoke 22 and the fixed core 24 are kept highly
accurately in coaxial alignment with each other, the movable core
26 can smoothly move reciprocally along the yoke 22 or the fixed
core 24, and side forces acting on the movable core 26 are reduced
to allow the movable core 26 to move reciprocally smoothly. Therefore,
hysteresis is reduced when the movable core 26 moves reciprocally,
and the solenoid 12 has good hysteresis characteristics.
[0150] A synthetic resin sealing body 40 which is molded over the
outer circumferential surface of the coil 32, a portion of the pipe
330, and a disk-shaped member 339 is disposed between the housing
14 and the coil 32. The synthetic resin sealing body 40 is molded
of a synthetic resin material integrally with a coupler 42. The
coupler 42 has a terminal 44 electrically connected to the coil
32 and having an exposed terminal end 44a that is electrically connected
to a power supply. The disk-shaped member 339 is made of a resin
material and fitted in an annular groove defined in the outer circumferential
surface of the fixed core 24.
[0151] The coil 32 has its outer circumferential surface covered
with the synthetic resin sealing body 40 for being stably protected.
If one of the ends of the coil 32 wound around the pipe 330 is covered
with a flange of the synthetic resin sealing body 40, the coil 32
is more stably protected.
[0152] In the fourth embodiment, the yoke 22 and the fixed core
24 are press-fitted in the hole 333 in the single pipe 330 which
is made of a nonmagnetic metal material (see FIG. 26). The pipe
330 keeps the yoke 22 and the fixed core 24 highly accurately in
coaxial alignment with each other, and allows the yoke 22 and the
fixed core 24 to be assembled with greater ease.
[0153] Specifically, the yoke 22 and the fixed core 24 are highly
accurately aligned coaxially with each other as they are held by
the inner circumferential surface of the hole 333 in the pipe 330
which is made of a nonmagnetic metal material. Since the yoke 22
and the fixed core 24 are kept highly accurately in coaxial alignment
with each other, the movable core 26 can smoothly move reciprocally
along the yoke 22 or the fixed core 24, and side forces acting on
the movable core 26 are reduced to allow the movable core 26 to
move reciprocally smoothly along the yoke 22 or the fixed core 24.
Therefore, the solenoid 12 provides good hysteresis characteristics
when the movable core 26 moves reciprocally.
[0154] In the fourth embodiment, furthermore, the coil 32 wound
around the pipe 330 is of square cross section, thereby minimizing
any gaps between stacked turns of the coil 32. Therefore, the total
cross-sectional area of the coil 32, i.e., the overall space occupied
by the coil 32 wound around the pipe 330, is smaller than that of
the conventional solenoid coil of circular cross section which has
the same number of turns as the coil 32.
[0155] Stated otherwise, the ratio of the cross-sectional area
of the conductor of the coil 32 to the space in which the coil 32
is wound, i.e., the conductor occupation ratio, may be greater than
that of the solenoid coil of circular cross section.
[0156] Since the space in which the coil 32 is wound can be reduced,
the pipe 330 can be reduced in size, resulting in a reduction in
the overall size of the solenoid 12.
[0157] If the space in which the coil 32 is wound is the same as
the space in which the solenoid coil of circular cross section is
wound, then the number of turns of the coil 32 of square cross section
on the pipe 330 is greater than that of the solenoid coil of circular
cross section. Accordingly, the solenoid 12 can produce greater
attractive forces (electromagnetic forces) than the solenoid coil
of circular cross section.
[0158] Furthermore, since the space in which the coil 32 is wound
can be reduced, the total dimension (total length) of the continuous
wire of the coil 32 can be reduced, and hence the resistance of
the coil 32 can be reduced. As a result, the electric power consumed
when the coil 32 is energized can be reduced.
[0159] If the coil 32 of square cross section has the same resistance
as the solenoid coil of circular cross section, then the number
of turns of the coil 32 wound around the pipe 330 is increased for
producing increased attractive forces (electromagnetic forces).
[0160] Moreover, the outer circumferential surface of the end of
the movable core 26 is disposed between the bottom 17 of the housing
14 and the tubular yoke 22 at a position which corresponds to the
inner wall surface of the bottom 17 of the housing 14 (see an encircled
portion D in FIG. 29). Therefore, magnetic fluxes that run from
the bottom 17 of the housing 14 to the movable core 26 are also
transferred between the inner wall surface of the bottom 17 and
the outer circumferential surface of the movable core 26 (see FIG.
30). Therefore, magnetic fluxes are smoothly transferred between
the bottom 17 of the housing 14 and the end of the movable core
26, so that an increased amount of magnetic fluxes can be generated
by the magnetic circuit.
[0161] Although certain preferred embodiments of the present invention
have been shown and described in detail, it should be understood
that various changes and modifications may be made therein without
departing from the scope of the appended claims.
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