Abstract: A control valve includes a magnetic pole member. An armature is slidably supported relative to the magnetic pole member for movement between a fully open position and a closed position. A biasing spring is disposed between the magnetic pole member and the armature for forcing the armature away from the magnetic pole member. A coil is placed about the magnetic pole member and the armature for inducing a magnetic field for moving the armature toward the magnetic pole member. One of either of the magnetic pole member or the armature has a recess for non-contactingly receiving the other when the armature moves between the fully open and closed positions. The control valve can be embodied as a normally open valve or a normally closed valve. The use of dual lateral poles and triple lateral poles create a flat magnetic force versus travel curve thereby allowing for greater proportional control of the valve.

Abstract: A valve includes a valve body, a flux tube, and a winding. The body defines first and second passageways, and a circular opening is defined in the second passageway providing fluid communication between the passageways. The flux tube has a closed end, an open end, and a hollow armature receiving section. The open end is in fluid communication with the first passageway. A spherical armature is disposed in the armature receiving section for reciprocating movement between a closed position sealing against the circular opening to prevent communication between the passageways and an open position spaced apart from the opening permitting communication between the passageways. The winding is disposed about the flux tube for electromagnetically positioning the armature. The flux tube forms a fluid tight pressure boundary between the winding and the passageways. A spring urges the armature toward one of the open position and the closed position.

Abstract: A control valve includes a magnetic pole member. An armature is slidably supported relative to the magnetic pole member for movement between a fully open position and a closed position. A biasing spring is disposed between the magnetic pole member and the armature for forcing the armature away from the magnetic pole member. A coil is placed about the magnetic pole member and the armature for inducing a magnetic field for moving the armature toward the magnetic pole member. One of either of the magnetic pole member or the armature has a recess for non-contactingly receiving the other when the armature moves between the fully open and closed positions. The control valve can be embodied as a normally open valve or a normally closed valve. The use of dual lateral poles and triple lateral poles create a flat magnetic force versus travel curve thereby allowing for greater proportional control of the valve.

Abstract: A coil assembly for a solenoid valve includes a bobbin formed from an electrically insulative material. A bore extends axially through the bobbin. A first flux ring having a sleeve extending axially from an annular base is mounted upon a first end of the bobbin with the sleeve extending into the bobbin bore. Similarly, a second flux ring also having a sleeve extending from an annular base is mounted upon a second end of the bobbin that is opposite from the first flux ring with its sleeve extending into the bobbin bore. The flux rings are formed from a magnetically permeable material that has a high heat conductivity. Magnet wire is wound upon the assembled bobbin and flux rings to form the coil assembly.

Abstract: A control valve for controlling fluid flow in a hydraulic control unit of a vehicular brake system includes a valve seat. A sleeve is mounted on the valve seat. An armature core is slidably received in the sleeve. The sleeve includes a first ferromagnetic portion adjacent the valve seat, a second ferromagnetic portion, and an annular region defining an area of increased magnetic reluctance. A part of the first portion of the sleeve defines a radial magnetic pole for the generally radial flow of magnetic flux from the armature to the sleeve. A portion of the valve seat adjacent the armature defines an axial magnetic pole for the generally axial flow of magnetic flux from the armature to the valve seat. Together, the generally radial flow of flux and the generally axial flow of flux generate a force urging the armature from an open position toward a closed position when the coil is energized.

Abstract: A control valve for controlling fluid flow in a hydraulic control unit of a vehicular brake system includes a valve seat. A sleeve is mounted on the valve seat. An armature core is slidably received in the sleeve. The armature core has a passage extending between first and second planar end surfaces of the armature core. An armature body is formed from a moldable material onto the armature core. The armature body has a central section received in the passage of the armature core, a first end section extending from the first end surface of the armature core, and a second end section extending from the second end surface of the armature core. This control valve is particularly adapted to be mounted in a bore of a housing of a hydraulic control unit of an electronically controlled vehicular brake system.

Abstract: A coil assembly for a solenoid valve includes a bobbin formed from an electrically insulative material. A bore extends axially through the bobbin. A first flux ring having a sleeve extending axially from an annular base is mounted upon a first end of the bobbin with the sleeve extending into the bobbin bore. Similarly, a second flux ring also having a sleeve extending from an annular base is mounted upon a second end of the bobbin that is opposite from the first flux ring with its sleeve extending into the bobbin bore. The flux rings are formed from a magnetically permeable material that has a high heat conductivity. Magnet wire is wound upon the assembled bobbin and flux rings to form the coil assembly.

Abstract: A method for assembling a hydraulic control unit of a vehicular brake system includes the following steps of: providing a sleeve having a closed end; sliding a spring over an armature to form an armature/spring subassembly; orientating the armature subassembly to produce a normally open valve or a normally closed valve; sliding the oriented armature/spring subassembly into the sleeve; sliding a valve seat into the sleeve; crimping a portion of the sleeve onto the valve seat to form a sleeve/valve seat subassembly; inserting the sleeve/valve seat subassembly into a bore of a housing. Two additional steps can be combined with the above listed steps to provide a method of assembling the control valve subassemblies described above on a hydraulic control unit. The additional steps include: inserting the sleeve/valve seat subassembly into a bore in a housing; and pressing a coil assembly about the sleeve.

Abstract: A solenoid coil inverted within a flux casing has at least one lead wire extending through a flux ring mounted in an end of the flux casing. The coil is coupled to a circuit board or overmolded lead frame which is positioned adjacent to a valve body with a solenoid valve sleeve extending through the circuit board or lead frame into the coil. A flexible coupling allows the coil to move relative to the circuit board or lead frame.

Abstract: A control valve for controlling fluid flow in a hydraulic control unit of a vehicular brake system includes a flux tube having an end cap, a thick tube section, and a thin tube section defining an interior volume. An armature is slidably received in the interior volume of the flux tube. A coil is provided about the flux tube. A collar covers a portion of the thin tube section and is spaced from the thick tube section so that an air gap is provided between the coil and the portion of the thin tube section not covered by the collar.

Abstract: A control valve for controlling fluid flow in a hydraulic control unit of a vehicular brake system includes a tube. A flux cap is pressed onto one end of the tube. A flux ring pole is pressed onto an opposite end of the tube. An armature is slidably received in the tube. A coil subassembly is provided about the tube, flux cap, and flux ring pole. A valve seat receives the flux ring pole. The valve seat is mounted in a bore of a hydraulic control unit of a vehicular brake system.

Abstract: This invention relates to an electro-hydraulic brake-by-wire system including a hydraulic pump and a plurality of valves to achieve a demanded braking force, and to achieve a desired brake pedal feel. The brake system includes a plurality of wheel brakes, a reservoir of hydraulic fluid, and a pump for selectively pumping hydraulic fluid from the reservoir and supplying pressurized hydraulic fluid to the wheel brakes for applying a braking force. The pump acts as a source of pressurized hydraulic fluid to the wheel brakes during normal brake apply, as well as during advanced braking functions as Antilock Braking (ABS), Traction Control (TC), or Vehicle Stability Control (VSC). An apply valve is associated with each of the wheel brakes for selectively permitting flow of pressurized hydraulic fluid from the pump to the associated wheel brake. A dump valve is associated with each of the wheel brakes for selectively permitting flow of pressurized hydraulic fluid from the associated wheel brake to the reservoir.

Abstract: A rotary solenoid valve for controlling pressurized fluid in a vehicular hydraulic system includes a housing having a bore. A valve body is mounted in the bore. The valve body includes an axial bore in fluid communication with a supply port, an output port, and a reservoir port. Each of the ports in the valve body is also in fluid communication with a corresponding fluid passage formed in the housing. A rotor is received in the axial bore of the valve body. The rotor includes at least one flat having a predetermined length so that the flat is in fluid communication with the ports in the valve body. An upper stator is mounted on the valve body about the rotor. A coil is mounted about the upper stator for generating a magnetic field to selectively rotate the rotor. Rotation of the rotor directs fluid through the valve between various ports as desired.

Abstract: A bobbinless coil for a solenoid valve having at least one free standing wire termination. The turns of the coil winding are bound together by an adhesive coating. An end cap having at least one terminal post is adjacent to one end of the coil winding with the post receiving and supporting the free standing wire termination. The terminal post and wire termination extend through an arpeture formed though a ferro-magnetic flux casing which encloses the winding and end cap. A flux ring is disposed in an open end of the flux casing and secured thereto to retain the winding and end cap therein.

Abstract: A solenoid coil inverted within a flux casing has at least one lead wire extending through a flux ring mounted in an end of the flux casing. The coil is coupled to a circuit board or overmolded lead frame which is positioned adjacent to a valve body with a solenoid valve sleeve extending through the circuit board or lead frame into the coil. A flexible coupling allows the coil to move relative to the circuit board or lead frame.

Abstract: A control valve for controlling fluid flow in a hydraulic control unit of a vehicular brake system includes a valve body. A flux tube is mounted on the valve body. An armature core having first and second ends and a longitudinal passage is slidably received in the flux tube. A bearing element is formed from a low-friction material. The bearing element includes a stem received into the longitudinal passage and an end cap having a diameter greater than a diameter of the armature core.

Abstract: A brake booster for a brake system of a vehicle, wherein the brake booster is in fluid communication with a source of pressurized fluid. The brake booster includes a housing having a bore formed therein and a conduit formed therein being in fluid communication with the bore and the source of pressurized fluid. The brake booster includes first and second pistons slidably disposed within the bore of the housing. The bore, the first piston, and the second piston define a fluid chamber in fluid communication with the conduit formed in the housing, wherein the volume of the chamber is defined by the position of the first piston relative to the second piston. The brake booster further includes a valve selectively preventing fluid flow in a direction from the chamber to the source of pressurized fluid via the conduit.

Abstract: A solenoid coil formed by winding a conductive foil tape upon a sleeve and method for making same. The coil includes a free standing wire termination which is wound into the coil. Alternately, the end of the foil tape can be folded to form a coil termination.

Abstract: An improved compensation piston arrangement for use with a dual circuit master cylinder having a single service piston for simultaneously pressurizing a first fluid chamber and a second fluid chamber, wherein the compensation piston arrangement provides for pressure balancing between the first fluid chamber and the second fluid chamber to compensate for minor normal differences between the first and second fluid chamber. The compensation piston arrangement includes a movable compensation piston slidably disposed within a bore of a compensation housing, wherein the housing defines a pair of end stops positioned on opposing sides of the compensation piston. The bore is in fluid communication with the fluid chambers such that the pressure within the first fluid chamber acts on a first side of the compensation piston, and the pressure within the second fluid chamber acts on a second end of the compensation piston which is opposite the first end.

Abstract: An improved force transfer arrangement for use in a dual circuit master cylinder having a pair of nested concentric pistons for pressurizing a pair of respective fluid chambers, wherein the force transfer arrangement imparts an input force from an input piston on a pair of pistons such that the pair of pistons can move relative to each other to compensate for different travel lengths. The invention discloses three embodiments of the improved force transfer arrangement. A first embodiment includes a hydraulic fluid chamber in fluid communication with the input piston and the pair of pistons. A second embodiment includes a circumferentially arranged ball mechanism positioned between the input piston and the pair of pistons. A third embodiment includes a notched lever ring assembly positioned between the input piston and the pair of pistons.