ELECTROMAGNET AND A METHOD FOR THE PRODUCTION THEREOF

Abstract

The electromagnet, at least comprising a magnet coil wound onto a coil core, a housing, a pole core, an armature, an armature rod and a yoke, should have a very low hysteresis of the force with a variable stroke at low manufacturing costs. The coil core is manufactured by jointly overmolding or overcasting the yoke, the pole core and the core flange with a plastic mass, wherein the axial intermediate space between the yoke and the pole core (4) is also filled with the plastic mass. Electromagnets of the described type are used for actuating fluid valves or couplings, preferentially in motor vehicles or in mobile working machines.

Claims

1. An electromagnet comprising: a magnet coil wound onto a coil core, a housing, a pole core, an armature, an armature rod and a yoke, wherein the coil core includes the yoke, the pole core and a core flange, the coil core being manufactured by jointly overmolding or overcasting the yoke, the pole core and the core flange with a plastic mass, and the axial intermediate space between the yoke and the pole core also being filled with the plastic mass.

2. The electromagnet according to claim 1, wherein the yoke comprising the armature is equipped with a flange that guides the magnetic flux from the housing to the armature.

3. The electromagnet according to claim 1, wherein an end plate is welded onto the yoke, which serves as a stop to the armature.

4. The electromagnet according to claim 1, wherein an end plate is pressed into the yoke that serves the armature as a stop.

5. The electromagnet according to claim 3, wherein the end plate has a hole or plurality of holes.

6. The electromagnet according to claim 1, wherein the core flange and the pole core are designed as one piece.

7. A method for the production of an electromagnet having a magnet coil wound onto a coil core, a housing, a pole core, an armature, an armature rod and a yoke, comprising: overmolding or overcasting the yoke, the pole core and the core flange with a plastic mass to produce the coil core; winding the coil core with the magnet coil; joining the housing around the yoke and the magnetic coil; reaming of an inner diameter of the coil core; joining the armature rod and the armature into the yoke; and welding the end plate onto the yoke or pressing the end plate into the yoke.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0028] FIG. 1 shows the electromagnet in detail.

[0029] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0031] The electromagnet (1) according to FIG. 1 is made up of at least one magnet coil (2) wound around a coil core (6), a housing (3), a pole core (4), an armature (5) having an armature rod (16) and a yoke (7).

[0032] The coil core (6) includes the yoke (7), the pole core (4) and the core flange (14), the coil core (6) being manufactured by jointly overmolding or overcasting the yoke (7), the pole core (4) and the core flange (14) with a plastic mass (8), and the axial intermediate space (10) between the yoke (7) and the pole core (4) also being filled with the plastic mass.

[0033] The pole core (4) is surrounded by a core flange (14) that guides the magnetic flux from the housing (3) to the pole core (4). Alternatively, the pole core (4) and the core flange (14) are designed as one piece.

[0034] The yoke (7) including the armature (5) is equipped with a flange (15) that guides the magnetic flux from the housing (3) to the armature (5). Alternatively, the flange (15) and the yoke (7) are two parts that are joined by compression.

[0035] An end plate (12) is welded onto the yoke (7), which serves as a stop for the armature (5) and has one hole or a plurality of holes (13). As an alternative to welding, the end plate (12) is joined by compression into the yoke (7).

[0036] The housing (3) comprises the magnet coil (2) and the yoke (7).

[0037] At least the following steps are provided for production of the electromagnets: [0038] overmolding or overcasting the yoke (7), the pole core (4) and the core flange (14) with a plastic mass (8) to produce the coil core (6); [0039] winding the coil core (6) with the magnet coil (2); [0040] joining the housing (3) around the yoke (7) and the magnetic coil (2); [0041] reaming of the inner diameter (11) of the coil core (6); [0042] joining the armature rod (16) and the armature (5) into the yoke (7); and [0043] welding the end plate (12 to the yoke (7).

LIST OF REFERENCE CHARACTERS

[0044] 1. electromagnet [0045] 2. magnet coil [0046] 3. housing [0047] 4. pole core [0048] 5. armature [0049] 6. coil core [0050] 7. yoke [0051] 8. plastic mass [0052] 9. intermediate space [0053] 10. inner diameter [0054] 11. end plate [0055] 12. hole [0056] 13. core flange [0057] 14. flange [0058] 15. armature rod