Abstract: A solenoid coil assembly having a first component member that is configured to support a coil and has a pair of terminal pins. The terminal pins are positioned for attachment to a structure such as a circuit board or lead frame. The first component member has pins for ultrasonic staking to a second component member. The second component member covers the first component member and the first and second component members provide an area for receiving and mounting the solenoid coil assembly to a valve assembly. The solenoid coil assembly positions first component member including the coil about the valve assembly.

Abstract: The invention is a two-stage, two-poppet prime valve assembly for use in high pressure applications such as vehicle braking systems. The valve assembly has two valve seats and two plungers for allowing the valve assembly to open under high pressure while providing minimal internal flow restrictions to enhance cold temperature and low pressure operation. The two-stage, two poppet valve assembly contains two separate flow paths, one being high pressure, relatively low flow called a stage one, and the other being relatively low pressure, high flow called a stage two. In addition, the valve incorporates a reverse flow bypass feature that is capable of controlling flow at very high pressure and allowing reverse flow with a very low pressure drop.

Abstract: A coil assembly includes a spool (102) having an upper flange (104), a medial flange (106) and a lower flange (108). A terminal groove (118) is established between the upper flange (104) and the medial flange (106), and a winding bay (110) is established between the medial flange (106) and the lower flange (108). Ramps (130) are formed in the groove (118) and at least two terminal posts (126), each having a foot (128), are inserted through the upper flange such that each foot (128) is disposed within the groove (118). Each terminal post (126) is movable between a winding position, wherein the foot (128) protrudes outwardly to facilitate engaging a coil wire end (132), and a retracted position, wherein the foot (128) is retracted behind the respective ramp (130).

Abstract: An anti-extrusion ring for use in conjunction with a vehicle solenoid valve has a plano-concave cross-section. The anti-extrusion ring is used to support a seal that seals the interface between a solenoid valve and a bore within a valve fitting. When the solenoid valve is installed in the valve fitting, a bore-to-ring interference area is formed between the bore and the anti-extrusion ring and a debris capture area is formed above the bore-to-ring interference area. Thus, when the anti-extrusion ring controllably fractures during installation of the solenoid valve with the bore or due to vibration, debris from the ring will be captured in the debris capture area and prevented from entering a fluid system in which the vehicle solenoid valve is used.

Abstract: An anti-extrusion ring for use in conjunction with a vehicle solenoid valve has a plano-concave cross-section. The anti-extrusion ring is used to support a seal that seals the interface between a solenoid valve and a bore within a valve fitting. When the solenoid valve is installed in the valve fitting, a bore-to-ring interference area is formed between the bore and the anti-extrusion ring and a debris capture area is formed above the bore-to-ring interference area. Thus, when the anti-extrusion ring controllably fractures during installation of the solenoid valve with the bore or due to vibration, debris from the ring will be captured in the debris capture area and prevented from entering a fluid system in which the vehicle solenoid valve is used.

Abstract: An apparatus and method for simultaneously setting the stroke and biasing force of a valve assembly, the apparatus utilizes a securement member which individually sets the biasing force of a valve assembly. The stop assembly allows a stop member, for setting the stroke of the valve assembly, and a securement member, for setting the biasing force of the valve assembly, to be secured simultaneously.

Abstract: The invention is a two-stage, two-poppet prime valve assembly for use in high pressure applications such as vehicle braking systems. The valve assembly has two valve seats and two plungers for allowing the valve assembly to open under high pressure while providing minimal internal flow restrictions to enhance cold temperature and low pressure operation. The two-stage, two poppet valve assembly contains two separate flow paths, one being high pressure, relatively low flow called a stage one, and the other being relatively low pressure, high flow called a stage two. In addition, the valve incorporates a reverse flow bypass feature that is capable of controlling flow at very high pressure and allowing reverse flow with a very low pressure drop.

Abstract: A vehicle solenoid valve includes an inlet port circumscribed by a rounded cup-shaped valve seat and an outlet port. A two-piece poppet is installed within the valve and includes a non-magnetic poppet shaft connected to a frustum-shaped poppet head. The poppet head includes an integrally formed, rounded nose that is sized and shaped to engage the rounded cup-shaped valve seat. The poppet is movable between an open configuration, wherein the rounded nose is distanced from the valve seat, and a closed configuration, wherein the rounded nose engages the valve seat to block fluid communication through the valve.

Abstract: A two-stage parallel spring solenoid valve (100) includes a coil housing (102) with a plunger tube (108) disposed therein. Disposed within the distal end (112) of the plunger tube (108) is a valve body (128) that includes a valve seat (138). A plunger assembly (160) is disposed within the plunger tube (108) and includes a plunger (162) and a plunger rod (184). An external spring (170) and an internal spring (190) are installed in parallel with each other within the plunger assembly (160). The valve (100) is movable from a closed configuration wherein the plunger rod (184) is seated against the valve seat (138) to block fluid flow through the valve (100), to an intermediate configuration wherein the plunger (162) further compresses the external spring (170) and the internal spring (190) and the plunger rod (184) remains seated against the valve seat (138), and to an open configuration, wherein the plunger rod (184) is distanced from the valve seat (138) to permit fluid flow through the valve (100).

Abstract: A vehicle solenoid valve includes an inlet port circumscribed by a rounded cup-shaped valve seat and an outlet port. A two-piece poppet is installed within the valve and includes a non-magnetic poppet shaft connected to a frustum-shaped poppet head. The poppet head includes an integrally formed, rounded nose that is sized and shaped to engage the rounded cup-shaped valve seat. The poppet is movable between an open configuration, wherein the rounded nose is distanced from the valve seat, and a closed configuration, wherein the rounded nose engages the valve seat to block fluid communication through the valve.

Abstract: A method for producing an interconnect from a first metal trace, through a dielectric, to a second metal trace. The method comprises the steps of heating a portion of the first metal trace to cause thermal expansion and at least partial melting thereof and heating a portion of the second metal trace to cause thermal expansion and at least partial melting thereof such that the thermal expansion of the traces causes at least one crack or fissure in the dielectric to be formed between the traces and such that the melting of the traces causes the metals to fuse together through the crack or fissure, thereby producing the interconnect from the first metal trace to the second metal trace. One of the metal traces may comprise a substantially square donut shape configuration having four interior edges portions, wherein the probability of a successful interconnection is increased due to the increased number of edges present on the tope layer from which a crack or fissure to the lower layer can form.

Abstract: A method for producing an interconnect from a first metal trace, through a dielectric, to a second metal trace. The method comprises the steps of heating a portion of the first metal trace to cause thermal expansion and at least partial melting thereof and heating a portion of the second metal trace to cause thermal expansion and at least partial melting thereof such that the thermal expansion of the traces causes at least one crack or fissure in the dielectric to be formed between the traces and such that the melting of the traces causes the metals to fuse together through the crack or fissure, thereby producing the interconnect from the first metal trace to the second metal trace. One of the metal traces may comprise a substantially square donut shape configuration having four interior edges portions, wherein the probability of a successful interconnection is increased due to the increased number of edges present on the top layer from which a crack or fissure to the lower layer can form.

Abstract: A solenoid coil attachment mechanism includes a coil assembly with a wire end that projects from the coil assembly and an extending elongated leg that includes a latching mechanism. A carrier has a wall with an opening receiving the leg of the coil assembly and has a wire guide that is funnel shaped, has an open end and receives the end of the wire. A circuit board is attached to the carrier and the wire end is soldered directly to the circuit board.