DE102007001141A1 - Magnetic coil and method for its production - Google Patents

Abstract

The present invention relates to a magnetic coil, comprising a winding support (8) with a winding (9) and a housing with a coil shell (3), a cover element (4) and a bottom element (5), wherein the coil shell (3), the cover element (4) and the bottom element (5) are made in one piece. Furthermore, the invention relates to a method for producing the magnetic coil and a blank from which a housing for the magnetic coil can be produced.

Description

State of the art

The The present invention relates to a magnetic coil and a method for their production.

Magnetic coils are used for example in solenoid valves in motor vehicles, for example in hydraulic vehicle brake systems. The known magnetic coils have basically a structure such that a winding support is wound with a winding, wherein the winding support is made of a plastic o. Ä., And a cylindrical coil casing surrounds the winding support together with winding. The coil shell is cup-shaped with a central bottom opening and a bottom opening opposite region is closed by a separate cover. The cover is connected to the coil shell, for example by welding. Such a solenoid is for example from the EP 1 307 369 A1 known. However, the known magnetic coils have the disadvantage that their production is relatively complicated and the magnetic coil is made of a plurality of individual components. It would thus be desirable if the solenoid could be improved to achieve a cost reduction and, in particular, a reduction in assembly effort.

Advantages of the invention

The Magnetic coil according to the invention with the features of claim 1, on the other hand, has the advantage that it can be produced easily and inexpensively. In this case, an assembly effort can be reduced to a minimum and the assembly in the shortest possible time. According to the invention while an entire iron circle of the magnetic coil from a component, which from a punched sheet metal component, which subsequently is bent in an advantageous manner is made.

The Housing comprises a coil shell, a cover element and a bottom element and is designed as a one-piece component. The housing has in the magnetic coil the task of magnetic return provide.

By this inventive use of punching and Bending techniques, it is also not mandatory that a Fixing a cover element or bottom element made on the coil shell is, because of the integral nature of all parts already together related.

The Subclaims show preferred developments of the invention.

Preferably is the housing of a one-piece sheet metal material produced.

The inventive method for producing a Magnetic coil, in particular for use in a solenoid valve, includes the following steps: First, a flat cut from a sheet metal material for the housing of the magnetic coil provided. The blank can, for example, by punching or by cutting, z. B. by means of a laser provided become. The blank of flat sheet material has a cover element, a bottom element and a coil shell, wherein in the cover element a first circular recess and in the bottom element a second circular recess is formed. Then done a deep drawing step of the first and second circular Recesses around a first and second magnetic transition region to form on the housing. It is a deep drawing of the first magnetic transition region opposite to a deep drawing direction of the second magnetic transition region. Subsequently the bottom element is bent by an angle of 90 °, so that the second magnetic transition region to an inside of the is still finished to be addressed magnetic coil. In a next Step is done by rolling the coil shell from the flat shape in a cylindrical shape. Then a winding carrier, on which a winding is applied, in the cylindrical shape of the rolled coil sheath inserted. The winding carrier can, if necessary, at the now almost finished housing be fixed. In a final step then the cover element bent over at an angle of 90 °, wherein the first magnetic transition region is directed on the cover element to the outside of the magnetic coil. Thus, the solenoid is completed. The invention Thus, the method is only possible by using forming steps a one-piece flat blank to the housing the solenoid. As a result, the inventive Procedure very simple and inexpensive become.

Alternatively, the method according to the invention may also comprise the following steps. The first three steps, ie, providing a flat blank of a sheet material, deep drawing the first and second circular recesses, and bending the bottom member 90 °, are performed as in the method described in the previous paragraph. Subsequently, however, in a next step, a bending of the bottom element takes place at an angle of 90 °, wherein the first magnetic transition region is directed to the outside of the magnetic coil. Thus, a manufacturing state of the housing is achieved, in which the bottom element and the cover element are set up by 90 ° relative to the still flat coil shell. Subsequently, an insertion of the winding carrier with a winding applied thereto, and as a last step, the coil shell is then wound around the inserted winding carrier into a cylindrical shape in order to complete the magnetic coil. This alternative method is particularly simple and inexpensive to carry out.

According to one further alternative method of the present invention the procedure the following steps. First, as in the others Method, a flat blank made of a sheet metal material or the like with a coil shell, a cover element and a bottom element and a first and a second circular recess provided in the cover element or in the bottom element. Subsequently the deep drawing step of the first and second circular steps takes place Punching in the cover element and in the bottom element in opposite Directions to provide the magnetic transition regions. In the third step, then rolls of the coil jacket and followed by insertion of the winding carrier with the applied winding. Then done as the last step, the bending of the cover element and the bottom element. The bending of the cover element and the bottom element can thereby in any order one after the other or at the same time.

Further The process according to the invention preferably comprises a step of joining first and second together Bumper edge of the coil jacket. This will be a special stable housing provided. The interconnection For example, by welding or gluing or Latching, d. h., form-fitting joining of the two abutting edges, respectively. Also, a connection of the two abutting edges be realized with each other that in the coil shell a Slit is provided, in which one of the two abutting edges is inserted. If necessary, can then again a fixing of the inserted abutting edge, z. B. by means Welding points o. Ä., Made.

According to one another preferred embodiment of the invention Method is the lid member and / or the bottom element in addition still connected to the coil shell. This can be done in the same way as a connection of the two abutting edges of the coil jacket take place, d. h., By gluing, welding, form-fitting or nesting.

Further The present invention relates to a one-piece blank for a housing of an iron circuit of a magnetic coil. The cut comprises a substantially rectangular coil case, an over a first connecting web arranged on the coil shell cover element and a via a second connecting web on the coil jacket arranged floor element. The cover element and the floor element are on opposite side areas arranged the coil shell. For ease of manufacture is the one-piece blank preferably symmetrical to a first and / or second center axis of the coil jacket. Of the one-piece blank is preferably made of a sheet metal material.

Preferably Both the lid member and the bottom member are at the center the opposite side portions of the magnetic coil arranged. This will result in a symmetrical cut in both central axes the coil sheath possible.

The Magnetic coil according to the invention is preferably in conjunction with solenoid valves, in particular solenoid valves in Motor vehicles, z. B. injectors or solenoid valves for used a brake system.

drawing

following will be preferred with reference to the accompanying drawings Embodiments of the invention described in detail. In the drawing is:

1 a schematic plan view of a blank for a housing of a magnetic coil according to a first embodiment of the invention,

2 a schematic side view of the in 1 shown blank,

3 a side view of the blank after a step of deep drawing,

4 a side view of the blank of 1 after a first step of forming,

5 a side view of the blank after a step of rolling the coil shell,

6 a view from the left of the in 5 shown state of the blank,

7 a schematic sectional view of the in 5 shown blank with inserted winding support,

8th a schematic sectional view of a finished magnetic coil according to the first embodiment,

9 to 11 partially sectional views illustrating a method for producing a magnetic coil according to a second Embodiment of the invention, and

12 and 13 partially sectional views of a magnetic coil to illustrate a method for producing the magnetic coil according to a third embodiment of the invention.

Preferred embodiments the invention

The following is with reference to the 1 to 8th a method for producing a magnetic coil 1 according to a first embodiment of the invention described in detail.

1 shows a blank 2 from a flat sheet material with a thickness D (see. 2 ). The cut 2 includes a substantially rectangular coil case 3 , at its four outer corners four rectangular recesses 3a . 3b . 3c and 3d are formed. The depth of the recesses 3a . 3b . 3c . 3d in the longitudinal direction XX and in the transverse direction YY of the blank 2 corresponds to the thickness D of the sheet material. The cut 2 further comprises a cover element 4 and a floor element 5 , which integral with the coil shell 3 are formed. For this purpose, a first connecting bridge 6 between the coil shell 3 and the lid member 4 provided and a second connecting bridge 7 is between the coil shell 3 and the floor element 5 provided (cf. 1 ). In the lid element 4 is also centrally a circular recess 4a formed as well as on the of the coil shell 3 extended end of the lid member 4 a fixing flange 4b educated. The floor element 5 also has a central, circular recess 5a and a fixing flange 5b on. How out 1 is apparent, is the blank 2 both symmetrical to the longitudinal axis XX and to the transverse axis YY. The opposite sides of the coil jacket 3 to which the cover element 4 and the floor element 5 are not arranged, are a first abutting edge 3e and a second abutting edge 3f ,

The inventive method for producing the magnetic coil 1 according to the first embodiment proceeds as follows. First, a cut 2 as in 1 shown, provided. The cut 2 can be z. B. by punching or by laser cutting from a sheet metal material can be provided. In a next step, a deep drawing of the recesses takes place 4a and 5a , For this purpose, the recesses 4a . 5a deep-drawn by means of appropriate tools, as in 3 shown. This results in the cover element 4 a first magnetic transition region 14 and on the floor element 5 a second magnetic transition region 15 , How out 3 it can be seen, is the deep drawing of the two recesses 4a . 5a opposite each other. That is, starting from the flat blank 2 becomes the first magnetic transition region 14 down and the second magnetic transition region 15 deep-drawn upwards. In a next step, as in 4 shown, the floor element becomes 5 by an angle α of 90 ° to the still flat coil shell 3 established. This is the second magnetic transition region 15 directed to the inside of the solenoid. In the next step, as in 5 and 6 shown, the coil sheath 3 rolled. D. h., From lying on both sides of the transverse axis Y flat portions of the coil shell these are rolled around, for example, a cylinder, so that the first and second abutting edge 3e . 3f get in touch with each other, as in 6 shown. As a result, the coil jacket 3 a cylindrical shape. The recesses provided at the corners of the coil jacket 3a and 3d take the fixing flange 5b of the floor element 5 on. During the rolling process, the fixing flange 5b also serve as a stop. In the next step, as in 7 shown is a externally prepared winding carrier 8th with a winding applied thereto 9 easy in the now unilaterally open, hollow cylindrical coil shell 3 inserted. The winding carrier 8th can be introduced loosely into the coil shell. In a last step, as in 8th is shown, then the cover element 4 by an angle β of 90 ° in the direction of the coil jacket 3 folded, so that a closed housing of the magnetic coil, comprising the coil sheath 3 , the floor element 5 and the lid member 4 is made.

The magnet coil according to the invention 1 is thus made by a simple and inexpensive process from a single blank 2 and a separate winding carrier 8th together with winding 9 produced. The case as it is from the blank 2 has been transformed, it does not necessarily require additional steps for a specific fixing of individual areas of the housing to each other, since all individual areas are related to each other. D. h., There must be no welding step for generating the housing of the solenoid provided. Of course, it is possible that, for example, for fixing the cover element 4 and the floor element 5 on the coil jacket 3 one or more welds between the two subregions are set. Also, individual sections could be glued together.

The following is with reference to the 9 to 11 a method for producing a magnetic coil 1 described according to a second embodiment of the invention, wherein identical or functionally identical parts are designated as in the first embodiment.

The method of the second embodiment corresponds to the in the 1 to 4 of the first embodiment illustrated steps. After bending the floor element 5 However, in the second exemplary embodiment, the winding carrier is then formed by the angle α 8th together with the winding wound on it 9 on the still flat coil jacket 3 hung up ( 9 ). In this case, the second magnetization region 15 be used as a guide device and positioning. In a next step, as in 10 shown, the cover element 4 by an angle β of 90 ° in the direction of the winding carrier 8th bent. That is, the lid member 4 and the floor element 5 are with respect to the still flat coil jacket 3 each bent by 90 °. As a last step, the coil sheath is then in the second embodiment 3 around the lid element 4 and the floor element 5 rolled around. This is the production of the magnetic coil 1 completed. As in the first embodiment described above, if desired, additionally fixing the individual areas, which the housing of the magnetic coil 1 form, be executed. Otherwise, this embodiment corresponds to the previous embodiment, so that reference can be made to the description given there.

The following is with reference to the 12 and 13 a method of manufacturing a magnetic coil according to a third embodiment of the invention described. Identical or functionally identical parts are again denoted by the same reference numerals as in the preceding embodiments. The third embodiment corresponds to those in the 1 to 3 shown steps the first and second embodiment. However, in the method according to the third embodiment, after the deep drawing step, the first and second magnetizing regions are formed 14 . 15 First, the step of rolling the coil jacket 3 , Subsequently, the with the winding 9 wound winding carrier 8th in the hollow cylindrical coil jacket 3 introduced. After that, the floor element 5 and the lid member 4 again bent by 90 ° to the solenoid coil 1 finish. The bending of the cover element 4 and the floor element 5 can be done simultaneously or in any order one after the other. If desired again, additional fixing measures of the individual regions of the housing of the magnetic coil can be provided with each other. Otherwise, this embodiment corresponds to the previous embodiments, so that reference can be made to the description given there.

The solenoid according to the invention can thus after the provision of the blank 2 and the deep drawing of the two magnetization areas 14 . 15 merely by forming the blank, in particular rolls or bending, are produced.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - EP 1307369 A1 [0002]

Claims (10)

Magnetic coil, comprising a winding carrier ( 8th ) with a winding ( 9 ) and a housing with a coil shell ( 3 ), a cover element ( 4 ) and a floor element ( 5 ), wherein the coil sheath ( 3 ), the cover element ( 4 ) and the floor element ( 5 ) are made in one piece. Magnetic coil according to claim 1, characterized in that the coil sheath ( 3 ), the cover element ( 4 ) and the floor element ( 5 ) are made of a one-piece sheet metal material. Method for producing a magnetic coil ( 1 ), comprising the steps of: a) providing a planar blank ( 2 ) of a sheet material, the blank ( 2 ) a coil sheath ( 3 ), a cover element ( 4 ) and a floor element ( 5 ), and wherein in the cover element ( 4 ) a first circular recess ( 4a ) and in the soil element ( 5 ) a second circular recess ( 5a ), b) deep-drawing the first recess ( 4a ) and the second recess ( 5a ) to a first magnetic transition region ( 14 ) and a second magnetic transition region ( 15 ), wherein a deep drawing direction of the first magnetic transition region ( 14 ) opposite to a deep drawing direction of the second magnetic transition region ( 15 ), c) bending the floor element ( 5 ) by an angle (α) of 90 °, so that the second magnetic transition region ( 15 ) is directed to an inside of the magnetic coil, d) rolls of the coil jacket ( 3 ) into a cylindrical shape, e) insertion of a winding carrier ( 8th ) with a winding applied thereto ( 9 ) in the rolled coil shell, and f) bending the cover element ( 4 ) by an angle (β) of 90 °, wherein the magnetic transition region ( 14 ) of the cover element ( 4 ) is directed to an outside of the magnetic coil. Method for producing a magnetic coil ( 1 ), comprising the steps of: a) providing a planar blank ( 2 ) of a sheet material, the blank ( 2 ) a coil sheath ( 3 ), a cover element ( 4 ) and a floor element ( 5 ), and wherein in the cover element ( 4 ) a first circular recess ( 4a ) and in the soil element ( 5 ) a second circular recess ( 5a ), b) deep-drawing the first recess ( 4a ) and the second recess ( 5a ) to a first magnetic transition region ( 14 ) and a second magnetic transition region ( 15 ), wherein a deep drawing direction of the first magnetic transition region ( 14 ) opposite to a deep drawing direction of the second magnetic transition region ( 15 ), c) bending the floor element ( 5 ) by an angle (α), so that the second magnetic transition region ( 15 ) is directed to an inside of the magnetic coil, d) bending the cover element ( 4 ) by an angle (β) of 90 °, wherein the first magnetic transition region ( 14 ) is directed to the outside of the magnetic coil, e) insertion of a winding carrier ( 8th ) with a winding applied thereto ( 9 ) between the cover element ( 4 ) and the floor element ( 5 ), and f) rolls of the coil jacket ( 3 ) in a cylindrical shape to the winding support ( 8th ) together with the winding ( 9 ) to surround. Method for producing a magnet coil, comprising the steps of: a) providing a planar blank ( 2 ) of a sheet material, the blank ( 2 ) a coil sheath ( 3 ), a cover element ( 4 ) and a floor element ( 5 ), and wherein in the cover element ( 4 ) a first circular recess ( 4a ) and in the soil element ( 5 ) a second circular recess ( 5a ), b) deep-drawing the first recess ( 4a ) and the second recess ( 5a ) to a first magnetic transition region ( 14 ) and a second magnetic transition region ( 15 ), wherein a deep drawing direction of the first magnetic transition region ( 14 ) opposite to a deep drawing direction of the second magnetic transition region ( 15 ), c) rolls of the coil jacket ( 3 ) in a cylindrical shape, d) insertion of a winding carrier ( 8th ) with a winding applied thereto ( 9 ) in the rolled coil shell, and e) bending the cover element ( 4 ) by an angle (β) of 90 ° and bending the bottom element ( 5 ) by an angle (α) of 90 °, wherein the bending of the lid member and the bottom member in any order can be performed sequentially or the bending of the lid member ( 4 ) and the floor element ( 5 ) can be done simultaneously. Method according to one of claims 3 to 5, characterized in that a first abutment edge ( 3e ) and a second edge ( 3f ) of the coil shell after rolling the coil shell are connected to each other. A method according to claim 6, characterized in that the first abutment edge ( 3e ) and the second edge ( 3f ) of the coil shell are interconnected by means of welding and / or gluing and / or latching and / or nesting. Method according to one of claims 3 to 7, characterized in that the cover element ( 4 ) with the coil jacket ( 3 ) is firmly connected and / or the floor element ( 5 ) with the coil jacket ( 3 ) is firmly connected. One-piece cut ( 2 ) for a housing of an iron circuit of a magnetic coil ( 1 ) comprising a substantially rectangular coil shell ( 3 ), via a first connecting bridge ( 6 ) on the coil shell ( 3 ) arranged cover element ( 4 ) and via a second connecting bridge ( 7 ) on the coil shell ( 3 ) arranged floor element ( 5 ), wherein the cover element ( 4 ) and the floor element ( 5 ) on opposite side regions of the coil jacket ( 3 ) are arranged and in the cover element ( 4 ) a recess ( 4a ) and in the soil element ( 5 ) a recess ( 5a ) is formed. Blank according to claim 9, characterized in that the cover element ( 4 ) and the floor element ( 5 ) are each disposed at a center of opposite sides of the coil shell.