STARTER SOLENOID WITH SPOOL FOR RETAINING COILS

• US 20120068476A1
• Filed: 09/21/2010
• Published: 03/22/2012
• Est. Priority Date: 09/21/2010
• Status: Active Grant

• Current Assignee: PHINIA TECHNOLOGIES INC.
• Original Assignee: Remy International Incorporated (BorgWarner Incorporated)
• Inventors: Bradfield, Michael D.
• Granted Patent: US 8,525,625 B2
• Time in Patent Office: Days
• US Class Current: 290/38.R
• CPC Class Codes: F02N 11/087 Details of the switching means in starting circuits, e.g. relays or electronic switches
• CPC Class Codes: H01H 50/20 movable inside coil and substantially lengthwise with respect to axis thereof; movable coaxially with respect to coil
• CPC Class Codes: H01H 50/44 Magnetic coils or windings
• CPC Class Codes: H01H 51/065 Relays having a pair of normally open contacts rigidly fixed to a magnetic core movable along the axis of a solenoid, e.g. relays for starting automobiles details H01H50/20

Abstract

A solenoid for a vehicle starter comprises a spool including a first coil bay, a second coil bay, and an interior passage defining an axial direction. A first coil is positioned in the first coil bay of the spool, and a second coil positioned in the second coil bay of the spool. A plunger is positioned within the interior passage of the spool and configured to move in the axial direction when the first coil is energized. The first coil bay is positioned adjacent to the second coil bay in the axial direction. The spool further includes two end flanges and a middle flange. The middle flange separates the first coil bay from the second coil bay.

Claims

1. A solenoid for a vehicle starter, the solenoid comprising:

a spool including a first coil bay, a second coil bay, and an interior passage defining an axial direction;

a first coil positioned in the first coil bay;

a second coil positioned in the second coil bay; and

a plunger positioned within the interior passage of the spool and configured to move in the axial direction when the first coil is energized.

2. The solenoid of claim 1 wherein first coil bay is positioned adjacent to the second coil bay in the axial direction.

3. The solenoid of claim 2 wherein the first coil bay is coaxial with the second coil bay along an axial centerline of the spool.

4. The solenoid of claim 3 wherein the spool further comprises a middle flange separating the first coil bay from the second coil bay.

5. The solenoid of claim 4 wherein the spool further comprises two end flanges, and wherein the middle flange is not centered on the spool between the two end flanges such that the first bay and the second bay are of different lengths.

6. The solenoid of claim 4 wherein the center flange is thicker than each of the two end flanges.

7. The solenoid of claim 4 wherein the middle flange includes a first winding protrusion with the second coil engaging the first winding protrusion.

8. The solenoid of claim 7 wherein the first winding protrusion is a first post extending radially outward on the flange.

9. The solenoid of claim 7 wherein the middle flange includes a second winding protrusion with the second coil engaging the second winding protrusion.

10. The solenoid of claim 4 wherein the middle flange includes a first slot and a second slot, wherein a start lead for the first coil extends through the first slot and a finish lead for the first coil extends through the second slot.

11. The solenoid of claim 10 wherein the first slot is tapered in a radial direction toward the axial centerline.

12. The solenoid of claim 10 wherein the spool further comprises an end flange including a first slot, a second slot, and a third slot, wherein the start lead for the first coil extends through the first slot and the finish lead for the first coil extends through the second slot, and wherein a start lead for the second coil extends through the first slot and a finish lead for the second coil extends through the third slot.

13. The solenoid of claim 1 wherein the first coil is a pull-in coil and the second coil is a hold-in coil.

14. The solenoid of claim 13 wherein the solenoid includes a plunger stop positioned in an end of the interior passage of the spool, wherein the pull-in coil is distanced from the plunger stop in the axial direction, and wherein the hold-in coil encircles the plunger stop.

15. The solenoid of claim 1 wherein the spool is a single molded component comprised of a glass filled nylon material.

16. A solenoid for a vehicle starter, the solenoid comprising:

a spool including a first end flange, a second end flange, and a middle flange;

a first coil positioned between the first end flange and the middle flange;

a second coil positioned between the middle flange and the second end flange; and

a plunger positioned within the spool and configured to move in an axial direction when the first coil is energized.

17. The solenoid of claim 16 wherein the middle flange is thicker than the first end flange or the second end flange.

18. The solenoid of claim 16 wherein the middle flange includes a plurality of coil mounting features positioned along the outer perimeter of the flange, and wherein the first coil and the second coil engage the coil mounting features.

19. A vehicle starter comprising:

an electric motor; and

a solenoid comprising;

a spool including a first coil bay, a second coil bay adjacent to the first coil bay;

a first coil positioned in the first coil bay;

a second coil positioned in the second coil bay such that the second coil is adjacent to the first coil in an axial direction; and

a plunger positioned within the spool and configured to move in the axial direction when the first coil is energized.

20. The vehicle starter of claim 19 wherein the first coil bay is positioned between a first end flange and a middle flange, and wherein the second coil bay is positioned between a second end flange and the middle flange.