Electromagnetic actuator with lamination stack-housing dovetail connection

Abstract

A method of joining a lamination stack of an electromagnetic actuator to a housing of the actuator includes providing a lamination stack having at least one surface feature. A mold is provided to define the housing. The lamination stack is inserted into the mold such that the surface feature of the lamination stack will define a mating surface feature in the housing. Material is cast around at least a portion of lamination stack to define the housing such that the surface feature of the lamination stack is engaged with the surface feature of the housing, thereby joining the lamination stack to the housing. The assembly of the lamination stack and housing is then removed from the mold.

What is claimed is:  
     
         1 . A method of joining a lamination stack of an electromagnetic actuator to a housing of the actuator, the method comprising: 
 providing a lamination stack having at least one shaped feature,    providing a mold to define the housing,    inserting the lamination stack into the mold such that said shaped feature of said lamination stack will define a mating shaped feature in said housing, and    casting material around at least a portion of said lamination stack to define said housing such that said shaped feature of said lamination stack is engaged with said shaped feature of said housing, thereby joining said lamination stack to said housing.    
     
     
         2 . The method according to    claim 1   , further comprising: removing said lamination stack together with the housing from said mold.  
     
     
         3 . The method according to    claim 1   , wherein said shaped feature of said lamination stack comprises one of a dovetail and a channel, and said shaped feature of said housing includes the other of said dovetail and said channel.  
     
     
         4 . The method according to    claim 3   , wherein said shaped feature of said lamination stack includes a dovetail and said shaped feature of said housing includes a channel receiving said dovetail.  
     
     
         5 . The method according to    claim 4   , wherein a pair of dovetails extend in spaced relation from a bottom surface of said lamination stack which mate with a pair of channels in said housing.  
     
     
         6 . The method according to    claim 1   , wherein aluminum is cast in the mold to define said housing.  
     
     
         7 . The method according to    claim 1   , wherein said lamination stack is provided by joining a plurality of individual lamination together, each of said individual laminations having a shaped feature which cooperate to define said shaped feature of said lamination stack.  
     
     
         8 . The method according to    claim 1   , wherein said shaped feature of said lamination stack is associated with a bottom surface of said lamination stack and said shaped feature of said housing is associated with an upper surface of said housing, and said casting is such that said when said shaped features are engaged, said upper surface of said housing contacts said bottom surface of said lamination stack.  
     
     
         9 . The method according to    claim 1   , wherein a plurality of shaped features are provided on a the lamination stack and a corresponding number of mating shaped features are defined in the housing upon casting said material.  
     
     
         10 . A lamination and housing assembly for an electromagnetic actuator comprising: 
 a lamination stack comprising a plurality of individual laminations, said lamination stack including a bottom surface and a shaped feature associated with said bottom surface, and    a housing having an upper surface and a shaped feature associated with said upper surface, said housing receiving said lamination stack such that said shaped feature of said lamination stack is engaged with said shaped feature of said housing, with said bottom surface of said lamination stack contacting said upper surface of said housing.    
     
     
         11 . The assembly according to    claim 10   , wherein said shaped feature of said lamination stack includes a dovetail and said shaped feature of said housing includes a channel receiving said dovetail.  
     
     
         12 . The assembly according to    claim 10   , wherein each of said individual laminations is of generally E-shape.  
     
     
         13 . The assembly according to    claim 10   , wherein said bottom surface of said lamination stack and said upper surface of said housing are each generally planar.  
     
     
         14 . The assembly according to    claim 10   , wherein said laminations are made of magnetic material and said housing is composed of aluminum.  
     
     
         15 . The assembly according to    claim 10   , wherein a plurality of shaped features are provided on said lamination stack and a corresponding number of shaped features are provided on said housing.