Solenoid with tolerance control

Claim 2

A solenoid device comprising an integrally molded bobbin defining an armature bore therein and including a collar portion of substantially less axial length than said bore and defining a passage therethrough of reduced transverse dimension relative to the remainder of said bore; a plunger extending into said bore through said collar portion and serving as an armature of said solenoid, said plunger having a close, sliding fit engagement within said collar portion which controls the movement of said plunger and substantially eliminates lateral movement thereof, said plunger having a loose, sliding engagement in the remainder of said bore; and coil means surrounding said bobbin for generating magnetic flux to move said plunger axially in said bore; said plunger formed of material having high magnetic permeability.

Claim 3

The solenoid device of claim 1, wherein said plunger and said collar portion interact to preclude relative rotary movement between said bobbin and said plunger.

Claim 4

The solenoid device of claim 2, wherein said plunger and said bore have noncircular complementary cross-sections.

Claim 5

The solenoid device of claim 1, wherein said bobbin is a glass-filled nylon member.

Claim 6

The solenoid device of claim 1, including a plurality of terminals for mounting said solenoid device to a substrate and for electrically connecting said solenoid to a voltage source.

Claim 7

The solenoid device of claim 1 wherein said collar portion is disposed at one end of said bore.

Claim 8

The solenoid device of claim 1, 2, 3, 5, or 6 wherein said plunger is of substantially uniform outside transverse dimension throughout the portion thereof which enters said bore.

Claim 9

A solenoid device comprising an integrally molded bobbin defining an armature bore therein and including a collar portion of substantially less axial length than said bore and defining a passage therethrough of reduced transverse dimension relative to the remainder of said bore said collar portion disposed at one end of the said bore; a plunger extending into said bore through said collar portion and serving as an armature of said solenoid, said plunger having a close, sliding fit engagement within said collar portion which controls the movement of said plunger and substantially eliminates lateral movement thereof, said plunger having a loose, sliding engagement in the remainder of said bore; a plug disposed in the other end of said bore for stopping said plunger; and coil means surrounding said bobbin for generating magnetic flux to move said plunger axially in said bore; said plug and said plunger formed of material having high magnetic permeability.

Claim 10

A solenoid device comprising an integrally molded bobbin defining an armature bore therein and including a collar portion of substantially less axial length than said bore and defining a passage therethrough of reduced transverse dimension relative to the remainder of said bore said collar portion disposed at one end of the said bore; a plunger extending into said bore through said collar portion and serving as an armature of said solenoid, said plunger having a close, sliding fit engagement within said collar portion which controls the movement of said plunger and substantially eliminates lateral movement thereof, said plunger having a loose, sliding engagement in the remainder of said bore; a plug disposed in the other end of said bore for stopping said plunger; and coil means surrounding said bobbin for generating magnetic flux to move said plunger axially in said bore; said plug and said plunger formed of material having high magnetic permeability.

Claim 11

The solenoid device of claim 8, wherein said solenoid includes a housing disposed around said bobbin.

Claim 12

The solenoid device of claim 9, wherein said solenoid includes a shell surrounding said coil means for protecting said coil means.

Claim 13

The solenoid of claim 10, wherein said solenoid includes a plurality of terminal pins for mechanically connecting said solenoid with a substrate and for electrically connecting said solenoid with a voltage source.

Claim 14

The solenoid device of claim 9, wherein said plunger and said collar portion interact to preclude relative rotary movement between said bobbin and said plunger.

Claim 15

The solenoid device of claim 12, wherein said plunger and said bore have noncircular complementary cross-sections.

Claim 16

The solenoid device of claim 9, wherein said bobbin is a glass-filled nylon member.

Claim 17

The solenoid device of claim 8, 9, 10, 11, 12, 13 or 14, wherein said plunger is of substantially uniform outside transverse dimension throughout the portion thereof which enters said bore.

Claim 18

An integrally molded solenoid bobbin for receiving an electrical coil therearound, said bobbin comprising an elongate member with a plunger bore therein and including a collar portion of substantially less axial length than said bore, said collar portion defining a passage therethrough of reduced transverse dimension relative to the remainder of said bore, whereby an armature plunger portion of predetermined cross-sectional shape and dimensions corresponding to said passage will have close finding fit engagement within said collar portion which controls the movement of said plunger portion and substantially eliminates lateral movement thereof, said plunger having loose sliding engagement in said remainder of said bore.

Claim 19

An integrally molded solenoid bobbin for receiving an electrical coil therearound, said bobbin comprising an elongate member with a plunger bore therein and including a collar portion of substantially less axial length than said bore, said collar portion defining a passage therethrough of reduced transverse dimension relative to the remainder of said bore, whereby an armature plunger portion of predetermined cross-sectional shape and dimensions corresponding to said passage will have close finding fit engagement within said collar portion which controls the movement of said plunger portion and substantially eliminates lateral movement thereof, said plunger having loose sliding engagement in said remainder of said bore.

Claim 20

The bobbin of claim 16, wherein said bobbin is made of glass-filled nylon.

Claim 21

The bobbin of claim 16, wherein said collar portion is disposed at one end of said bore.

Claim 22

The bobbin of claim 16, wherein said plunger and said collar portion interact to preclude relative rotary movement between said bobbin and said plunger.

Claim 23

The bobbin of claim 16, wherein said plunger and said bore have noncircular complementary cross-sections.