Starter solenoid with rectangular coil winding
First Claim
Patent Images
1. A solenoid for a vehicle starter, the solenoid comprising:
- a first coil comprised of a first length of rectangular wire forming windings and leads, the first coil a pull-in coil for the vehicle starter;
a second coil axially adjacent to the first coil, the second coil a hold-in coil for the vehicle starter, wherein the windings of the first coil are not in contact with windings of the second coil such that the first length of rectangular wire is separated from the second coil except for the leads of the first coil extending in an axial direction across the windings of the second coil;
a spool with an internal passage and a middle flange, the first coil and the second coil wound on the spool with the middle flange positioned between the first coil and the second coil, the middle flange separating the first coil from the second coil in the axial direction with substantially no ferromagnetic material positioned between the first coil and the second coil in the axial direction, the middle flange including at least one slot configured to receive a lead of the first coil; and
a plunger configured to move in an axial direction within the internal passage of the spool when the first coil is energized.
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Abstract
A solenoid for a vehicle starter includes a pull-in coil made of a length of rectangular wire and a hold-in coil adjacent to the pull-in coil. A plunger is configured to move in an axial direction when the pull-in coil made of rectangular wire is energized. The pull-in coil and the hold-in coil are positioned on a spool with the plunger slideably positioned within a central passage of the spool. The plunger is configured to engage a plunger stop when the pull-in coil is energized. In at least one embodiment, the hold-in coil is separated from the plunger stop in the axial direction and the hold-in coil encircles the plunger stop.
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Citations
17 Claims
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1. A solenoid for a vehicle starter, the solenoid comprising:
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a first coil comprised of a first length of rectangular wire forming windings and leads, the first coil a pull-in coil for the vehicle starter; a second coil axially adjacent to the first coil, the second coil a hold-in coil for the vehicle starter, wherein the windings of the first coil are not in contact with windings of the second coil such that the first length of rectangular wire is separated from the second coil except for the leads of the first coil extending in an axial direction across the windings of the second coil; a spool with an internal passage and a middle flange, the first coil and the second coil wound on the spool with the middle flange positioned between the first coil and the second coil, the middle flange separating the first coil from the second coil in the axial direction with substantially no ferromagnetic material positioned between the first coil and the second coil in the axial direction, the middle flange including at least one slot configured to receive a lead of the first coil; and a plunger configured to move in an axial direction within the internal passage of the spool when the first coil is energized. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A vehicle starter comprising:
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an electric motor configured to drive a pinion; and a solenoid comprising; a metallic case; a plunger configured to move in an axial direction within the metallic case; a plunger stop configured to engage the plunger when the plunger is in a plunger stop position; a first coil positioned within the metallic case and comprised of a length of rectangular wire, the coil configured to move the plunger in an axial direction to the plunger stop position when the coil is energized; a second coil positioned within the metallic case, the second coil adjacent to the first coil in the axial direction but not in contact with the first coil and substantially no ferromagnetic material positioned between the first coil and the second coil in the axial direction; a non-ferromagnetic separator positioned axially between the first coil and the second coil, the non-ferromagnetic separator including at least one substantially rectangular slot providing at least one passage in the axial direction completely across a perimeter of the non-ferromagnetic separator, wherein a lead for the first coil extends through the at least one slot; and a contact configured to close a current path to the electric motor when the plunger is in the plunger stop position. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A solenoid for a vehicle starter, the solenoid comprising:
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a non-ferromagnetic spool including a first end flange, a second end flange, a middle flange, and an internal passage, wherein a first coil bay is provided between the first end flange and the middle flange, and wherein a second coil bay is provided between the middle flange and the second end flange; a first coil comprised of plurality of windings of rectangular wire wound around the spool on the first coil bay, the plurality of windings of the first coil retained completely between the first end flange and the middle flange, the first coil further comprising a lead configured to engage a middle slot on the middle flange, extend across the second coil bay, and engage at least one slot on the second end flange; a second coil adjacent to the first coil in an axial direction and substantially no ferromagnetic material positioned between the first coil and the second coil in the axial direction, the second coil including a plurality of windings of wire wound around the spool on the second coil bay and retained completely between the second end flange and the middle flange, the second coil further comprising a lead engaging the at least one slot on the second end flange; and a plunger configured to move in the axial direction when the first coil and the second coil are energized.
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Specification