Idle Air Control Valve With Plastic Housing And Retention Features

Abstract

A method provides a plastic housing for an actuator. The actuator has a stator assembly coupled to a connector structure and a rotor assembly that rotates with respect to the stator assembly. The method inserts the stator assembly with connector structure connected thereto into an interior of the plastic housing until a surface of the stator assembly engages a surface of the plastic housing, with an annular end of the plastic housing extending beyond an adjacent annular surface of the connector structure. The annular end of the housing is heated and deformed to capture the annular surface of the connector structure, thereby coupling the plastic housing to the connector structure.

1 - 10 . (canceled) 
     
     
         11 . A method of providing a plastic housing for an actuator, the actuator having a stator assembly coupled to a connector structure, and a rotor assembly constructed and arranged to rotate with respect to the stator assembly, the method comprising the steps of:
 inserting the stator assembly with connector structure connected thereto into an interior of the plastic housing until a surface of the stator assembly engages a surface of the plastic housing, with an annular end of the plastic housing extending beyond an adjacent annular surface of the connector structure, and   heating and deforming the annular end of the housing to capture the annular surface of the connector structure, thereby coupling the plastic housing to the connector structure.   
     
     
         12 . The method of  claim 11 , wherein the deforming step includes rolling the heated annular end of the plastic housing. 
     
     
         13 . The method of  claim 11 , further comprising:
 providing tabs in the interior of the plastic housing and providing associated pockets in the stator assembly such that upon the inserting step, a tab interlocks with an associated pocket, thereby preventing rotation of the stator assembly with respect to the plastic housing.   
     
     
         14 . The method of  claim 11 , wherein the plastic housing includes an integral flange, the flange including bolt holes there-through, the method further comprising:
 inserting a metal compression limiter in each bolt hole.   
     
     
         15 . The method of  claim 11 , wherein prior to the inserting step, the method further comprises:
 providing ferrous flux ring structure about a portion of the stator assembly.   
     
     
         16 . The method of  claim 11 , wherein prior to the deforming step, the method further comprises:
 orienting the connector structure to one of 360° positions with respect to the annular wall of the plastic housing.