Abstract: A solenoid (10) includes a shell (12), a lower stator member (20) associated with the shell, and an upper stator member (30) in the shell. The upper stator member is separate from the lower stator member and has a wire receiving member (34). A half bobbin (40) is associated with the upper stator member and has a wire receiving portion (44). Wire is wound directly about the portion of the half bobbin and directly about the member of the upper stator member to define a winding (46). An armature (54) is movable with respect to at least the lower stator member upon energizing the winding.

Abstract: A solenoid (10) includes a shell (12), a lower stator member (20) associated with the shell, and an upper stator member (30) in the shell. The upper stator member is separate from the lower stator member and has a wire receiving member (34). A half bobbin (40) is associated with the upper stator member and has a wire receiving portion (44). Wire is wound directly about the portion of the half bobbin and directly about the member of the upper stator member to define a winding (46). An armature (54) is movable with respect to at least the lower stator member upon energizing the winding.

Abstract: A cylindrical-walled seat element (50) in a double-pintle (42) EEGR valve (20) is a machined metal part in which two substantially identical apertures (62, 64) collectively span essentially a semi-circumference of the seat element wall (52) and are separated by a narrow axial stabilizer bar (80) in that wall.

Abstract: A double-pintle valve (20) has two seats (54, 56) each circumscribing a respective through-hole for exhaust gas flow. The through-hole of one seat (56) is large enough diametrically to allow the closure (46) that seats on the other seat (54) to pass through during fabrication of the valve. The closure (46) seats substantially on a radially outermost portion of a frustoconical surface zone (54B) of the seat (54) and the other closure (48) seats substantially on a radially innermost portion of a frustoconical surface zone (56B) of the one seat (56) when the valve is disallowing flow.

Abstract: A powdered metal bearing (40) that guides a pintle (42) in an EGR valve (20) is sealed against infiltration of exhaust gases by mechanical processing or by applying a sealant.

Abstract: An apparatus, system and method for releasably retaining a helical compression spring with respect to a threaded fastener. The threaded fastener includes an annular ridge that is sized and configured to retain the helical compression spring without interfering with the operation of the helical compression spring.

Abstract: Improved accuracy and response of an EEGR valve (60) are obtained by novel constructional features of an upper stator member (194), a lower stator member (174), a bearing guide member (140), and a shell (64), and various inter-relationships between them for improved concentricity of parts, stable and accurate positioning of parts relative to each other, and better resistance to muddy water intrusion at an ambient air space (76) that provides for ambient air to pass through for cooling the valve. A lower stator member (174) has a through-hole (184) to which a bearing member (140) that guides a pintle shaft (114) is concentrically disposed. A frusto-conical surface (182) extends from through-hole (184) to the ambient air space (76).

Abstract: A non-metallic bobbin (22) has features on a radial flange (28) which allow magnet wire (MW) that forms an electromagnet coil (114) on the bobbin core (24) to be tensioned throughout. An end segment of magnet wire is wrapped around a post (56) on the bobbin flange, and the magnet wire runs in tension generally diametrically across the bobbin to pass through slots (66, 68) in opposite walls of an electric-terminal-receiving socket (60) also on the flange. The wire runs in grooved tracks (74, 70) proximate the socket to pass around the perimeter edge of the flange to the opposite flange face where it is wound in tensioned convolutions around the core to create the coil. It then runs in tension from the coil around the perimeter edge of the flange to pass through a second socket (62) having the same associated features as the first socket (60). From there the tensioned magnet wire extends back across the bobbin to be tied to the post.

Abstract: Improvements in a head (44) of a pintle (38) and associated valve seat (34) of an EGR valve (10) for providing a desired geometric relationship between respective tapered surfaces (36c, 104) that close against each other and for reducing tendency for carbon build-up. A blind hole (108) extends centrally axially inward from the lower end face (107) of the pintle head, reducing the mass, and hence thermal inertia, but without affecting the desired geometric relationship of the seat to the pintle head.

Abstract: An improved electrical connection is provided between terminals (T) mounted in a sensor cap (26) that closes an otherwise open end of a cylindrical EEGR valve body shell (24), and terminals (98, 99) mounted in sockets (100, 102) on a solenoid coil assembly (70) that operates the EEGR valve from an engine electrical control that is connected via a wiring harness connector plug mating with an external plug of sensor cap (26) containing terminals (T). The end portions of terminals (T) that mate with terminals (98, 99) are forked blades having reduced thickness from an adjoining portion, thereby providing greater resilient flexibility for a better and more reliable electrical connection.

Abstract: Improvements in an armature-pintle assembly (36) and related stator structure (56, 58) of a solenoid actuator used in an EGR valve (10) for controlling the EGR valve opening in accordance with an electric control current from an engine control system. The stator structure defines an air gap (80) disposed in proximate surrounding relationship to a cylindrical tubular walled portion (126) of the armature (40). The air gap is defined by two confronting, but axially spaced apart, axially extending wall portions (66, 82) of the stator structure. A non-magnetic sleeve member (110) has a tubular cylindrical side wall disposed radially between these stator wall portions and the cylindrical tubular walled portion of the armature. The sleeve has an end wall disposed for abutment with the armature to define a limit of axial travel for the armature-pintle assembly and to provide a spring seat for a helical coiled spring that biases the armature-pintle assembly normally closed.

Abstract: A circular metal clinch ring (36) secures a cap (26) to a shell (24) of an EEGR valve (20). The clinch ring has a plurality of integral sharp pointed barbs (210) that partially embed in polymeric material of the cap. The ring constrains the shell and cap against relative axial and circumferential movement, with some barbs being pointed in one sense and others in the opposite sense to resist relative circumferential movement between the cap and the shell in both circumferential senses. A wave spring washer (186) is disposed to maintain the axial position of the bobbin-mounted solenoid coil (70) within the valve.

Abstract: An attachment for paint cans and the like is disclosed. The attachment includes a trough shaped pouring spout which is fitted to the rim of a can by a channel section member which snaps over the rim. The spout has a curved knife edge at its outer end and slopes upwardly away from the can so that, at the end of a pouring operation, the edge will cleanly cut off the flow of paint and residual paint will flow back into the can. The curved knife edge allows the attachment to also be used for scraping paint from a roller.