CN118234983A - Miniature medium isolation swinging diaphragm valve with enhanced magnetic flux loop - Google Patents

Abstract

The magnetically operated valve includes a combination valve body and bobbin including a bobbin portion supporting a magnetic coil and a valve body portion housing a magnetic pole and an armature. The armature is movable under magnetic force to operate the valve operator to control fluid flow through the valve. The valve includes a flux support having a first end positioned in close contact with the pole and a second end passing through the valve body portion of the combined valve body and bobbin to position the second end adjacent the armature. The flux support is formed as a single piece of material, such as soft iron that is stamped or otherwise formed in a single piece. The valve operator may be configured as a rocker with a fluid isolation diaphragm and the valve may have a three-way valve configuration or a two-way valve configuration.

Description

Miniature medium isolation swinging diaphragm valve with enhanced magnetic flux loop

Technical Field

The present application relates to fluid control devices such as valves, and in particular to media isolation rocking diaphragm valves, which are commonly used in vitro diagnostic devices, analytical chemistry instruments, and other liquid handling applications.

Background

Conventional media isolation valves operate by magnetic forces that are applied via a magnetic flux circuit comprising a plurality of components. A typical valve design includes a flux carrier, a flux coupler, a magnetic coil wound on a plastic bobbin, a pole, and an armature to form a flux circuit. There is a flux loss as long as the flux path must traverse the boundary between the magnetic components or the gap of non-magnetic material such as, for example, plastic or air. One way to overcome the inefficiency of the magnetic flux circuit is to make the magnetic flux circuit components large enough to provide the necessary magnetomotive force required for a given particular application, but for many applications a compact size is desirable and thus increasing the component size is an undesirable approach.

In one type of valve configuration, commonly referred to as a rocking diaphragm media isolation valve, such valves use a polymer rocker that pivots on a centrally located stainless steel pivot pin. The diaphragm isolates the flow path for the medium (typically a liquid) from the other components of the valve that form the magnetic flux circuit. Such a valve may be configured as a three-way valve with two valve seats arranged on opposite sides of the rocker and three ports comprising two inlet ports and one common outlet port. The rocker pivots to allow flow from one or the other of the inlet ports through the outlet port. Other valves may be configured as two-way valves with one valve seat on one end of the rocker and with two ports, including an inlet port and an outlet port, whereby the rocker pivots to open or close a fluid path from the inlet port through the outlet port. In either configuration, the valve is actuated by an electromagnet that pulls the armature from an unactuated position (in which the armature is held away from the fixed pole by a coil spring) to an actuated position (in which the armature is magnetically attracted against the pole). Typically, such valves use copper magnetic coils wound on plastic bobbins to induce a magnetic field to magnetize the ferritic steel components positioned around the coils that form the magnetic flux circuit.

As mentioned above, the flux support members typically form part of a flux circuit. Typical flux carriers for conventional three-way and two-way valves may be two-piece carriers injection molded from metal. In such two-piece bracket configurations, the flux bracket typically has an upper portion that is metal injection molded to the pole, and to assemble the valve, the upper bracket is slid onto the lower bracket and the two halves are welded together. Alternatively, the flux support may be a stamped and bent soft iron into which the poles are press-fit. Additional stamped flux coupler components may then be fitted and crimped (crimp) into the openings of the flux frame to complete the flux circuit. Upon assembly, the armature moves through a centrally located bore in the flux coupler. In both configurations, the valve uses an actuator assembly that is self-contained (self-contained) and structurally separated from the fluid medium by a diaphragm. Conventional arrangements employing two-piece or stamped bent brackets and additional flux couplers are multi-piece structures that are complex to manufacture and have significant difficulty in reducing size to achieve a more compact overall valve arrangement. Conventional arrangements also have significant gaps between the components that interrupt the flux circuit, which makes it difficult to further reduce the gaps, which is required to maximize magnetic operation.

Disclosure of Invention

The present application provides an enhanced rocking diaphragm media isolation solenoid valve that has a compact configuration as compared to conventional configurations while maintaining efficient performance. In order to reduce the size of the media isolation solenoid valve while still providing sufficient magnetomotive force, higher magnetic flux circuit efficiency may be achieved by minimizing gaps between the magnetic flux circuit members. The valve arrangement in the present application achieves higher flux circuit efficiency by incorporating a one-piece molded soft iron flux carrier in the valve arrangement. A first end of the one-piece flux support is crimped into intimate contact with or secured to the pole piece and a second end of the flux support, opposite the first end, is passed through a combined valve body and bobbin (bobbin) component in proximity to the moving armature. This configuration creates an efficient and miniaturized flux circuit with minimal gaps between the flux circuit components, which improves efficiency when direct current is applied to the winding magnet coil wound around the bobbin portion of the combined valve body and bobbin component. A flux circuit with this configuration is measured to have at least 20% higher force from the electromagnet acting on the armature than when the bracket does not pass through the combined valve body and bobbin component.

By configuring the flux carrier as a single piece and combining the poles and armature as described, the overall size of the valve assembly is miniaturized, more compact than conventional configurations. Furthermore, the valve assembly process is simplified since no connection is required between the valve actuator and the valve operator. Another advantage is that the assembly and arrangement of the components forming the flux circuit are positioned relative to a single component comprising a one-piece flux carrier.

In an exemplary embodiment, the valve includes a base plate with a plurality of ports and a rocker that rotates about a rocker pivot pin, the rocker engaging a diaphragm that opens and closes the ports based on the position of the rocker. The valve includes a combination valve body and spool member that houses a rocker arm. The combination valve body and bobbin member defines a tubular bore extending along an axis perpendicular to the rocker arm and which receives the armature and the pole. The armature is axially movable within the bore relative to the pole and in a direction perpendicular to the rocker surface. The valve also includes a flux support having a first end coupled or secured to the pole member and a second end opposite the first end, the second end being received within the combined valve body and bobbin component adjacent the armature. The bobbin portion of the combined valve body and bobbin assembly supports a wound magnetic coil that surrounds the bore and is coupled to a power source. When the magnetic coil is energized by a power source, a magnetic field is generated to move the armature axially within the bore to control the position of the rocker. The first end of the flux support may be crimped to the pole to couple or secure the first end of the flux support to the pole. The valve may further include a first resilient member positioned between a shoulder on the armature and the flux carrier, and the first resilient member biases the armature against the rocker. The valve may further include a second resilient member biasing the armature opposite the first resilient member.

Accordingly, one aspect of the present invention is a valve having an enhanced magnetic flux circuit configuration to allow efficient operation with a compact size with minimal gaps between components of the magnetic flux circuit. In an exemplary embodiment, a valve includes a base plate having a plurality of fluid flow paths including at least one inlet path and an outlet path for fluid flow through the base plate; a combined valve body and spool secured to the base plate, the combined valve body and spool including a spool portion supporting a magnetic coil and a valve body portion housing a valve operator movable between a first operator position and a second operator position to control fluid flow through the base plate; the bobbin portion of the combined valve body and bobbin further defines a bobbin aperture; a magnetic pole fixed in the winding pipe hole; an armature positioned within the bobbin aperture and adjacent the magnetic pole, wherein the armature is movable relative to the magnetic pole through the bobbin aperture along a stroke distance from the first armature position to the second armature position by energizing the magnetic coil to operate the valve operator to control fluid flow through the base plate; and a flux support having a first end positioned in intimate contact with the pole and having a second end passing through the valve body portion of the combination valve body and bobbin to position the second end adjacent the armature. The flux support may be configured as a single piece of stamped material or otherwise formed as a single piece using any suitable manufacturing process, such as, for example, wire EDM (wire EDM), water jet cutting, laser cutting, metal injection molding or machining processes, and the like. The valve operator may be configured as a rocker with a fluid isolation diaphragm attached to the rocker, and the valve may have a three-way valve or a two-way valve configuration.

In an exemplary embodiment of the valve, the first end of the flux support is crimped and fixed to the pole.

In an exemplary embodiment of the valve, the magnetic pole has an outer end that extends through the first end of the magnetic flux carrier, and the first end of the magnetic flux carrier extends around the outer end of the magnetic pole.

In an exemplary embodiment of the valve, the second end of the flux support has a curved portion to allow the second end to pass through the valve body portion and the second end of the flux support extends around the armature.

In an exemplary embodiment of the valve, the flux support is a single piece of unitary material.

In an exemplary embodiment of the valve, the valve body portion and the bobbin portion are integrated into a single piece of molding material to form a combined valve body and bobbin.

In an exemplary embodiment of the valve, the valve further comprises a first resilient member housed within the valve body portion, the first resilient member biasing the armature toward the first armature position such that when the armature is in the first armature position when the magnetic coil is de-energized, the armature interacts with the first end of the valve operator to position the valve operator in the first operator position.

In an exemplary embodiment of the valve, the first resilient member is compressed between the shoulder of the armature and the second end of the flux carrier.

In an exemplary embodiment of the valve, the valve further comprises a second resilient member housed within the valve body portion, the second resilient member biasing the valve operator toward the second operator position opposite the first resilient member; and the force exerted by the first resilient member is greater than the force exerted by the second resilient member such that when the armature is in the first armature position when the magnet coil is de-energized, the armature positions the valve operator in the first operator position due to the greater force of the first resilient member, and when the armature is in the second armature position when the magnet coil is energized, the armature is spaced apart from the valve operator and the valve operator is moved to the second operator position by the force of the second resilient member.

In an exemplary embodiment of the valve, the second resilient member is compressed between the inner surface of the valve body portion and the second end of the valve operator.

In an exemplary embodiment of the valve, the first elastic member and the second elastic member are coil springs.

In an exemplary embodiment of the valve, a rocker is housed within the valve body portion of the combined valve body and spool, and the rocker is rotatable about a pivot pin between a first rocker position corresponding to the first operator position and a second rocker position corresponding to the second operator position to control fluid flow through the base plate.

In an exemplary embodiment of the valve, movement of the rocker positions the resilient diaphragm against a portion of the plurality of fluid flow paths to control fluid flow through the base plate, and wherein the diaphragm fluidly isolates the plurality of fluid flow paths from the valve body portion of the combination valve body and spool.

In an exemplary embodiment of the valve, the rocker is made of a polymeric material and the diaphragm is overmolded onto the rocker.

In an exemplary embodiment of the valve, the diaphragm has a sealing bead positioned at or adjacent to a periphery of the diaphragm to fluidly isolate the plurality of fluid flow paths from the valve body portion of the combined valve body and spool.

In an exemplary embodiment of the valve, the valve is configured as a three-way valve in which the plurality of fluid flow paths includes a first inlet path, an outlet path, and a second inlet path positioned on an opposite side of the outlet path relative to the first inlet path.

In an exemplary embodiment of the valve, when the valve operator is in the first operator position, the valve operator seals the first inlet path to prevent fluid flow between the first inlet path and the outlet path, and the valve operator lifts from the second inlet path to allow fluid flow between the second inlet path and the outlet path; and wherein when the valve operator is in the second operator position, the valve operator seals the second inlet path to prevent fluid flow between the second inlet path and the outlet path, and the valve operator lifts from the first inlet path to allow fluid flow between the first inlet path and the outlet path.

In an exemplary embodiment of the valve, the valve is configured as a two-way valve in which the plurality of fluid flow paths comprises only a first fluid flow path and a second fluid flow path, one of the first fluid flow path or the second fluid flow path acting as an inlet path and the other of the first fluid flow path or the second fluid flow path acting as an outlet path.

In an exemplary embodiment of the valve, when the valve operator is in the first operator position, the valve operator seals the first fluid flow path to prevent fluid flow between the first fluid flow path and the second fluid flow path; and wherein when the valve operator is in the second operator position, the valve operator is lifted from the first fluid flow path to allow fluid flow between the first fluid flow path and the second fluid flow path.

These and further features of the present invention will be apparent with reference to the following specification and drawings. In the description and drawings, particular embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited correspondingly in scope. On the contrary, the invention includes all alternatives, modifications and equivalents as may be included within the spirit and scope of the appended claims. Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

Drawings

FIG. 1 is a drawing depicting a top perspective view of an exemplary embodiment of a media isolation solenoid valve.

Fig. 2 is a drawing depicting a bottom perspective view of the media isolation solenoid valve of fig. 1 showing the bottom plate and ports illustrating a three-way valve configuration.

Fig. 3 is a drawing depicting a top perspective view of the media isolation solenoid valve removal housing of fig. 1 and 2.

Fig. 4 is a drawing depicting a cross-sectional view of the media isolation solenoid valve shown in fig. 3.

FIG. 5 is a drawing depicting a cross-sectional view of an alternative exemplary media isolation solenoid valve having a two-way valve configuration.

Detailed Description

Embodiments of the present application will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. It will be appreciated that the figures are not necessarily drawn to scale.

The present application provides an enhanced media isolation solenoid valve having a compact configuration as compared to conventional configurations while maintaining efficient performance. Fig. 1 is a drawing depicting a top perspective view of an exemplary embodiment of a media isolation solenoid valve 10. The valve 10 includes a valve housing 12 that houses the solenoid actuated and operator components of the valve 10. An electrically insulating wire 14 extends from the valve housing 10 for connection to a power source (not shown) for supplying electrical current to the electromagnetic components of the valve housed within the valve housing. The environmental seal is enhanced by an insulating cap 16, which insulating cap 16 is positioned on the valve housing 12 and through which the insulating wire 14 extends. The valve housing 10 is mounted on a combination valve body and spool 18, which will be described in further detail below. The combination valve body and spool 18 is mounted and secured to the base plate 20 opposite the valve housing. The valve housing 10, the combination valve body and spool 18, and the base plate 20 may be secured to one another using any suitable fastening mechanism (such as, for example, a bolt or screw fastening assembly) or ultrasonic welding or similar manufacturing process.

Fig. 2 is a drawing depicting a bottom perspective view of the media isolation solenoid valve 10 of fig. 1, showing the base plate and valve ports formed into the base plate. The example valve 10 of fig. 1 and 2 has a three-way valve configuration in which a plurality of valve ports are formed into a base plate, and the plurality of valve ports include a first inlet port 22, an outlet port 24, and a second inlet port 26 positioned on an opposite side of the outlet port from the first inlet port. The valve ports may be sealed by respective sealing elements 29, which may be, for example, O-ring seals or similar elastic seals. As explained in further detail below, in the three-way valve configuration, fluid flows through either the first inlet port 22 or the second inlet port 26, as well as through the floor, and out the outlet port 24. Accordingly, the valve 10 includes a valve operator movable between a first operator position and a second operator position, whereby the valve operator operates by closing or sealing the first inlet port 22 when the second inlet port 26 is open, and vice versa.

Fig. 3 is a drawing depicting a top perspective view of the media isolation solenoid valve 10 of fig. 1 and 2 with the housing 12 removed, and fig. 4 is a drawing depicting a cross-sectional view of the media isolation solenoid valve 10 depicted in fig. 3. As described above, the combined valve body and bobbin 18 is mounted and fixed to the base plate 20. The combined valve body and spool 18 includes a spool portion 28 and a body portion 30 that are integrally formed as a single piece. The bobbin portion 28 and the valve body portion 30 may be integrally formed from a molded material, such as, for example, a molded plastic material. The bobbin portion 28 is configured as a tubular member having an outer surface and an inner surface, wherein the inner surface defines a bobbin aperture 32. The bobbin portion 28 acts as a support structure for the magnetic coil 34, which includes a wire wound around the outer surface of the bobbin portion 28. The bobbin aperture 32 of the bobbin portion 28 accommodates a fixed pole 36 and a movable armature 38, the movable armature 38 being movable through the bobbin aperture 32 of the bobbin portion 28 in a longitudinal direction through the bobbin aperture 32 between a first armature position and a second armature position. As described in greater detail below, movement of the armature controls movement of a valve operator housed within valve body portion 30 to control fluid flow through the base plate ports. The wire 14 is connected to an electrical pin 15 that is electrically connected to the magnetic coil 34. The cap 16 shown in fig. 1 and 2 may be snapped onto an electrical connector through which the insulated wire extends.

To reduce the size of the media isolation solenoid valve while still providing sufficient magnetomotive force, higher magnetic flux circuit efficiency may be achieved by minimizing gaps between the magnetic flux circuit members. The configuration of the valve 10 achieves higher magnetic flux circuit efficiency by integrating the one-piece magnetic flux support 40 into the valve structure. The flux support 40 may be configured as a single piece of unitary material, such as, for example, a soft iron single piece that is stamped to form such a single piece, or otherwise formed as a single piece using any suitable manufacturing process (such as, for example, wire cutting, water jet cutting, laser cutting, metal injection molding, or machining processes, etc.). The one-piece flux support 40 has a first curved portion 41 to place the first end 42 adjacent the pole 36. The first end 42 of the one-piece flux support 40 may be crimped into intimate contact with the pole 36 and may be coupled or secured to the pole 36, in particular, by a crimping operation. In the example configuration shown in fig. 3 and 4, the outer end 35 of the pole 36 extends through the bobbin portion 28 of the combined valve body and bobbin 18 and through the first end 42 of the flux support 40, this first end 42 of the flux support 40 extending circumferentially around the outer end 35 of the pole 36. A second end 44 of the flux support 40, opposite the first end 42, passes through the valve body portion 30 of the combined valve body and bobbin 18 to be positioned adjacent the movable armature 38. In the example of fig. 3 and 4, the valve body portion 30 defines a body aperture 46 and the one-piece flux support 40 has a second curved portion 47 such that the second end 44 of the flux support 40 extends through the body aperture 46 with the second end 44 extending around the armature 38. In this manner, the one-piece flux support 40 has a "C" shape with a first end 42 crimped into close contact with the pole 36 or secured to the pole 36 and a second end 44 positioned adjacent the armature 38. As described above, the armature is movable between the first armature position and the second armature position through the bobbin aperture 32 of the bobbin portion 28. Because the armature 38 is movable, there is a slight gap between the armature 38 and the second end 44 of the flux carrier 40 to allow for such armature movement, but this gap can be minimized by passing the second end 44 through the valve body portion 30 to be in the vicinity of the armature 38.

The pole 36 has an inner end 37 opposite the outer end 35. The armature 38 has a first end 48 and a second end 50 opposite the first end 48, wherein the first end 48 of the armature is positioned adjacent the inner end 37 of the pole 36. The first end 48 of the armature and the inner end 37 of the pole 36 define a travel distance 52 therebetween that corresponds to the movable distance of the armature 38 between a first armature position spaced from the pole and a second armature position substantially abutting the pole. Accordingly, fig. 4 depicts the armature in a first armature position. The magnetic coil 34 is electrically connected with the electrical terminal 15 and thus with the wire 14. When the magnetic coil 34 is energized, a magnetic field is created that generates a magnetic flux that travels through the valve components (including, in particular, the magnetic pole 36, the flux support 40, and the armature 38). The poles, armatures and flux carriers are all made of ferrous materials commonly used in the solenoid art. The generated magnetic force attracts the armature 38 from a first armature position spaced from the pole, across the stroke distance 52, and toward the fixed pole 36 to a second armature position substantially against the pole, thereby operating the valve operator component of the valve 10, as described in greater detail below.

As described above, the valve 10 configuration employs a one-piece flux carrier having a first end that is crimped into intimate contact with or secured to the pole and a second end that passes through the valve body portion of the combined valve body and bobbin to be in proximity to the movable armature. This configuration creates an efficient and miniaturized magnetic flux circuit with minimal gaps between the magnetic flux circuit components, providing enhanced efficiency when direct current is applied to a magnetic coil wrapped around the bobbin portion of the combined valve body and bobbin. It was measured that the flux circuit employing this configuration had at least 20% higher force in terms of magnetic force acting on the armature than conventional configurations in which the flux support did not pass through the bobbin or valve body member. Further, by configuring the flux carrier as a single piece and combining the poles and armatures as described above, the overall size of the valve assembly is miniaturized to be more compact than conventional configurations. Further, the valve assembly process is simplified because no connection is required between the valve actuator and the valve operator, and the mating and alignment of the components forming the flux circuit are each positioned in a single portion of the one-piece flux carrier.

By energizing the magnet coils, the armature can move through the bobbin aperture relative to the pole along a stroke distance from the first armature position to the second armature position. Movement of the armature in turn operates the valve operator to move between a first operator position and a second operator position to control fluid flow through the base plate via the inlet port and the outlet port. The magnetic flux circuit member of valve 10 is particularly suited for use in a rocker diaphragm media isolation valve configuration in which the valve operator includes a rocker to which is attached a resilient diaphragm that seals the fluid media flow area from the valve body portion that includes the magnetic flux circuit member. Accordingly, movement of the rocker positions the diaphragm against a portion of the plurality of fluid flow paths to control fluid flow through the base plate, wherein the diaphragm fluidly isolates the plurality of fluid flow paths from the valve body portion of the combined valve body and bobbin including the magnetic flux circuit member.

As depicted in the cross-sectional view of fig. 4, the valve 10 includes a valve operator having a rocker 60 that pivots or "swings" about a pivot pin 62 between a first rocker position and a second rocker position. The first rocker position corresponds to the first operator position and the second rocker position corresponds to the second operator position. The rocker may be made of a polymeric material that does not affect the magnetic flux, and the pivot pin may be made of any suitable hard material, such as stainless steel or hard plastic. The rocker arm 60 is received within the valve body portion 30 of the combination valve body and bobbin 18. The valve operator further comprises a diaphragm 64 made of an elastic material, which is attached to the rocker 60. For example, the elastomeric membrane 64 may be overmolded onto the polymer rocker 60. The cross-sectional view of fig. 4 also depicts the fluid flow path through the base plate 20. In particular, the first inlet port 22 is in fluid communication with the first inlet path 23, the outlet port 24 is in fluid communication with the outlet path 25, and the second inlet port 26 is in fluid communication with the second inlet path 27. In the three-way valve configuration, depending on the position of the rocker 60 of the valve operator, either the first inlet path 23 or the second inlet path 27 is in fluid communication with the outlet path 25, the other of the first inlet path 23 or the second inlet path 27 being sealed and closed about the outlet path 25 by the diaphragm 64 of the valve operator.

The diaphragm 64 may include a sealing bead 66 molded or otherwise shaped and positioned at or adjacent to the periphery of the diaphragm 64. The sealing bead 66 is compressed between the valve body portion 30 of the combination valve body and bobbin 18 and the base plate 20. In this manner, the sealing beads 66 of the diaphragm 64 seal the fluid flow path from the magnetic flux circuit member, thereby isolating the magnetic flux circuit member from the fluid medium (which is typically a liquid for this type of valve). To enhance the closure of the inlet flow path, the diaphragm 64 may further include a first gasket 68 for sealing and closing the first inlet path 23 and a second gasket 70 for sealing and closing the second inlet path 27.

The valve 10 may further include a first resilient member 72 that is received within the body portion 30 of the combined valve body and spool 18. The armature 38 may include a shoulder 74 positioned adjacent the armature second end 50. As shown in fig. 4, the first resilient member 72 is compressed between the second end 44 of the flux support 40 and the shoulder 74 of the armature 38. Accordingly, the first resilient member 72 operates to bias the armature 38 against the first end 59 of the rocker 60 toward the first armature position, which tends to rotate the rocker 60 in a clockwise direction about the pivot pin 62. Thus, in the first position, the armature is fully biased against the first end 59 of the rocker 60, which will bias the rocker toward the first rocker position. The valve 10 may also include a second resilient member 76 that is also received within the body portion 30 of the combined valve body and spool 18. As shown in fig. 4, the second resilient member 76 is compressed between the inner surface of the valve body portion 30 and the second end 61 of the rocker 60 opposite the first end 59. Accordingly, the second resilient member 76 biases the rocker toward the second rocker position, opposite the bias of the first resilient member 72 relative to rotation about the pivot pin 62, and thus the second resilient member tends to rotate the rocker 60 about the pivot pin 62 in a counterclockwise direction. The first elastic member and the second elastic member may be configured as coil springs. The armature is axially movable within the bore relative to the pole and in a direction perpendicular to the rocker surface.

The rocking diaphragm valve 10 operates as follows. In the exemplary embodiment, first resilient member 72 has a biasing force that is greater than a biasing force of second resilient member 76. Accordingly, when the magnetic coil 34 is de-energized, the greater biasing force of the first resilient member 72 will overcome the lesser biasing force of the second resilient member 76. Thus, the first resilient member 72 biases the armature 38 to a first armature position spaced from the pole 36, which also rotates the rocker 60 clockwise to a maximum extent to the first rocker position. This in turn presses the diaphragm against the bottom plate 20 at the first inlet channel 23, which diaphragm seals and closes the first inlet path 23 with respect to the outlet path 25. This in turn also lifts the diaphragm from the base plate 20 at the second inlet path 27 as the rocker rotates clockwise to a maximum extent to the first rocker position, placing the second inlet path 27 in fluid communication with the outlet path 25. Since this state corresponds to the initial state when the magnetic coil is de-energized, the first inlet port 22 (first inlet path 23) is commonly referred to as a normally closed port, while the second inlet port 26 (second inlet path 27) is commonly referred to as a normally open port.

As described above, when the magnetic coil 34 is energized, a magnetic field is created that creates a magnetic flux that travels through the valve components (including, in particular, the magnetic poles 36, the flux support 40, and the armature 38 that form a magnetic flux circuit). The magnetic force generated attracts the armature 38 from a first armature position positioned spaced from the pole 36, across the stroke distance 52, and toward the fixed pole 36 to a second armature position substantially abutting the pole 36. In this manner, the armature 38 is movable relative to the pole 36 in a longitudinal direction along the bobbin bore 32 in a direction perpendicular to the rocker surface with which the armature contacts. The magnetic force from the solenoid 34 overcomes the biasing force of the first resilient member 72 and thus the armature 38 lifts from the rocker 60 and the first end 59 of the rocker 60 is not biased by the first resilient member 72. With the biasing force of the first resilient member 72 removed, the biasing force of the second resilient member 76 against the second end 61 of the rocker 60 is no longer opposite/counter, and thus the biasing force of the second resilient member 76 causes the rocker to rotate counterclockwise to the greatest extent to the second rocker position. This in turn presses the diaphragm against the bottom plate 20 at the second inlet path 27, sealing and closing the second inlet path 27 from the outlet path 25. As the rocker rotates counterclockwise to a maximum extent to the second rocker position, this in turn lifts the diaphragm from the base plate 20 at the first inlet path 23, which places the first inlet path 23 in fluid communication with the outlet path 25. When the magnetic coil 34 is de-energized, the greater biasing force of the first resilient member 72 will return the valve 10 to the initial state described above, wherein the armature 38 returns to the first armature position.

Fig. 5 is a drawing depicting a cross-sectional view of an alternative exemplary media isolation solenoid valve 10a having a two-way valve configuration. The two-way valve 10a has common components with the three-way valve 10 in fig. 1 to 4, and thus like components are identified with like reference numerals. In particular, the components of the magnetic flux circuit that drive the valve operator may take either a two-way valve configuration or a three-way valve configuration. The main difference is that in the two-way valve embodiment 10a of fig. 5, there are only two ports, namely a first port 22a in fluid communication with a first fluid flow path 23a, and a second port 26a in fluid communication with a second fluid flow path 27 a. The first and second fluid flow paths are joined by a connecting fluid flow path that extends along the back of the valve body to the second port 26a. Either port may act as an inlet port or an outlet port depending on the direction of fluid flow, and the dedicated outlet port 24 and associated outlet flow path 25 of the three-way valve arrangement are omitted in the two-way valve arrangement.

In other respects, the two-way valve 10a operates similarly to the three-way valve 10 in the previous embodiment. As described above, the first elastic member 72 has a biasing force greater than that of the second elastic member 76. Accordingly, when the magnetic coil 34 is de-energized, the greater biasing force of the first resilient member 72 will overcome the lesser biasing force of the second resilient member 76. Thus, the first resilient member 72 biases the armature 38 to a first armature position spaced from the pole 36, which maximizes clockwise rotation of the rocker 60 to the first rocker position. This in turn presses the diaphragm against the base plate 20 at the first fluid flow path 23a, thereby sealing and closing the first fluid flow path 23a. In the two-way valve configuration, this will block any fluid flow between the first fluid flow path 23a and the second fluid flow path 27a as the rocker is maximally rotated clockwise to the first rocker position. Since this state corresponds to the initial state when the magnetic coil is deenergized, the two-way valve 10a is generally called a normally closed valve.

As described above, when the magnetic coil 34 is energized, a magnetic field is created that creates a magnetic flux that travels through the valve components (including, in particular, the magnetic poles 36, the flux support 40, and the armature 38 that form a magnetic flux circuit). The magnetic force generated attracts the armature 38 from a first armature position spaced from the pole 36, across the stroke distance 52, and toward the fixed pole 36 to a second armature position substantially abutting the pole 36. The magnetic force from the solenoid 34 overcomes the biasing force of the first resilient member 72 and thus the armature 38 lifts from the rocker 60 and the first end 59 of the rocker 60 is not biased by the first resilient member 72. With the biasing force of the first resilient member 72 removed, the biasing force of the second resilient member 76 against the second end 61 of the rocker 60 is no longer opposite and the biasing force of the second resilient member 76 causes the rocker to rotate counterclockwise to a maximum extent to the second rocker position. This in turn lifts the diaphragm from the base plate 20 at the first fluid flow path 23a as the rocker is rotated counterclockwise to a maximum extent to the second rocker position, placing the first fluid flow path 23a in fluid communication with the second fluid flow path 27 a. When the magnetic coil 34 is de-energized, the greater biasing force of the first resilient member 72 returns the valve 10a to the initial state described above and the armature 38 returns to the first armature position.

Accordingly, one aspect of the present invention is a valve having an enhanced magnetic flux circuit configuration to allow efficient operation with compact dimensions within a minimum gap between magnetic flux circuit components. In an exemplary embodiment, a valve includes a base plate having a plurality of fluid flow paths including at least one inlet path and an outlet path for fluid flow through the base plate; a combined valve body and spool secured to the base plate, the combined valve body and spool including a spool portion supporting the magnetic coil and a valve body portion housing a valve operator movable between a first operator position and a second operator position to control fluid flow through the base plate; the bobbin portion of the combined valve body and bobbin further defines a bobbin aperture; a magnetic pole fixed in the winding pipe hole; an armature positioned within the bobbin aperture and adjacent the magnetic pole, wherein the armature is movable relative to the magnetic pole through the bobbin aperture along a stroke distance from the first armature position to the second armature position by energizing the magnetic coil to operate the valve operator to control fluid flow through the base plate; and a flux support having a first end positioned in close contact with the pole and a second end passing through the valve body portion of the combined valve body and bobbin to position the second end adjacent the armature. The valve may include one or more of the following features, alone or in combination.

Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. Furthermore, while a particular feature of the invention may have been described with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.

Claims (20)

1. A valve, comprising:

a base plate having a plurality of fluid flow paths for fluid flow through the base plate, the fluid flow paths including at least one inlet path and an outlet path;

A combination valve body and spool secured to the base plate, the combination valve body and spool including a spool portion supporting a magnetic coil and a valve body portion housing a valve operator movable between a first operator position and a second operator position to control fluid flow through the base plate;

the spool portion of the combination valve body and spool further defines a spool aperture;

a magnetic pole fixed in the winding pipe hole;

an armature positioned within the bobbin aperture and adjacent the magnetic pole, wherein upon energizing the magnetic coil, the armature is movable relative to the magnetic pole through the bobbin aperture along a stroke distance from a first armature position to a second armature position to operate the valve operator to control fluid flow through the base plate; and

A flux support having a first end positioned in close contact with the pole and a second end passing through the valve body portion of the combined valve body and bobbin to position the second end adjacent the armature.

2. The valve of claim 1, wherein a first end of the flux support is crimped and secured to the pole.

3. The valve of any of claims 1-2, wherein the pole has an outer end that extends through the first end of the flux support and the first end of the flux support extends around the outer end of the pole.

4. A valve according to any one of claims 1 to 3, wherein the second end of the flux support has a curved portion to allow the second end to pass through the valve body portion and the second end of the flux support extends around the armature.

5. The valve of any of claims 1 to 4, wherein the flux support is a single piece of unitary material.

6. The valve of any one of claims 1 to 5, wherein the flux carrier is a single piece of soft iron formed by one of a stamping, wire cutting, water jet cutting, laser cutting, metal injection molding, or machining process.

7. The valve of any of claims 1-6, wherein the valve body portion and the bobbin portion are integrated into a single piece of molded material to form the combined valve body and bobbin.

8. The valve of any one of claims 1 to 7, further comprising a first resilient member housed within the valve body portion, the first resilient member biasing the armature toward the first armature position, whereby when the armature is in a first armature position when the magnetic coil is de-energized, the armature interacts with a first end of the valve operator to position the valve operator in the first operator position.

9. The valve of claim 8, wherein the first resilient member is compressed between a shoulder of the armature and a second end of the flux carrier.

10. The valve according to any one of claims 8 to 9, further comprising a second resilient member housed within the valve body portion, opposite the first resilient member, the second resilient member biasing the valve operator toward the second operator position; and

The force applied by the first resilient member is greater than the force applied by the second resilient member such that when the armature is in the first armature position when the magnetic coil is de-energized, the armature positions the valve operator in the first operator position due to the greater force of the first resilient member, and when the armature is in the second armature position when the magnetic coil is energized, the armature is spaced apart from the valve operator and the valve operator is moved to the second operator position by the force of the second resilient member.

11. The valve of claim 10, wherein the second resilient member is compressed between an inner surface of the valve body portion and the second end of the valve operator.

12. The valve according to any one of claims 8 to 11, wherein the first elastic member and the second elastic member are coil springs.

13. The valve of any one of claims 1 to 12, wherein the valve operator includes a rocker housed within a valve body portion of the combined valve body and spool, and the rocker is rotatable about a pivot pin between a first rocker position corresponding to the first operator position and a second rocker position corresponding to the second operator position to control fluid flow through the base plate.

14. The valve of claim 13, wherein the valve operator further comprises a resilient diaphragm attached to the rocker, wherein movement of the rocker positions the diaphragm against a portion of the plurality of fluid flow paths to control fluid flow through the base plate, and wherein the diaphragm fluidly isolates the plurality of fluid flow paths from a valve body portion of the combined valve body and spool.

15. The valve of claim 14, wherein the rocker is made of a polymeric material and the diaphragm is overmolded onto the rocker.

16. The valve of any one of claims 14 to 15, wherein the diaphragm has a sealing bead positioned at or adjacent a periphery of the diaphragm to fluidly isolate the plurality of fluid flow paths from a valve body portion of the combined valve body and spool.

17. The valve according to any one of claims 1 to 16, wherein the valve is configured as a three-way valve in which the plurality of fluid flow paths includes a first inlet path, an outlet path, and a second inlet path positioned on an opposite side of the outlet path relative to the first inlet path.

18. The valve of claim 17, wherein when the valve operator is in the first operator position, the valve operator seals the first inlet path to prevent fluid flow between the first inlet path and the outlet path, and the valve operator lifts from the second inlet path to allow fluid flow between the second inlet path and the outlet path; and

Wherein when the valve operator is in the second operator position, the valve operator seals the second inlet path to prevent fluid flow between the second inlet path and the outlet path, and the valve operator lifts from the first inlet path to allow fluid flow between the first inlet path and the outlet path.

19. The valve according to any one of claims 1 to 16, wherein the valve is configured as a two-way valve in which the plurality of fluid flow paths includes only a first fluid flow path and a second fluid flow path, one of the first fluid flow path or the second fluid flow path serving as an inlet path and the other of the first fluid flow path or the second fluid flow path serving as an outlet path.

20. The valve of claim 19, wherein when the valve operator is in the first operator position, the valve operator seals the first fluid flow path to prevent fluid flow between the first fluid flow path and the second fluid flow path; and

Wherein when the valve operator is in the second operator position, the valve operator is lifted from the first fluid flow path to allow fluid flow between the first fluid flow path and the second fluid flow path.