Solenoid Housing and Method of Making the Same

Abstract

The invention relates to a solenoid housing fabricated by a method which allows a manufacturer to produce a high performing product while minimizing manufacturing complexity and time. The instant invention uses cold-forging techniques to reduce the need for fine machining processes.

What is claimed is: 
     
         1 ) A method of providing a solenoid housing, comprising the steps of:
 providing a cylinder of malleable material having a first part and a second part, said first part having a first-part perimeter and said second part having a second-part perimeter;   reducing a size of the first-part perimeter to be less than a size of the second-part perimeter;   compressing at least a portion of said second part in a direction towards said first part to produce a flattened disk;   providing said cylinder of malleable material with a non-magnetic region; and   extending a bore from said first part toward said second part to at least a distance beyond said non-magnetic region.   
     
     
         2 ) The method of providing a solenoid housing according to  claim 1 , wherein the step of compressing at least a portion of said second part in a direction towards said first part to produce a flattened disk also comprises the following step:
 providing a protrusion on said second part.   
     
     
         3 ) The method of providing a solenoid housing according to  claim 2 , further comprising a step of:
 providing a cup around said cylinder of malleable material.   
     
     
         4 ) The method of providing a solenoid housing according to  claim 3 , wherein the step of providing a cup around said cylinder of malleable material further comprises the steps of:
 providing a sheet of malleable material;   raising a perimeter of said sheet to produce a raised perimeter;   extending said raised perimeter to define a cup with a base;   and providing a recess in said base of said cup.   
     
     
         5 ) The method of providing a solenoid housing according to  claim 3 , wherein the cup is provided by machining a cup-bore into a cylinder. 
     
     
         6 ) The method of providing a solenoid housing according to  claim 3 , wherein the step of providing a cup around said cylinder of malleable material is performed by a method selected from the group consisting of:
 assembling, riveting, press-fitting, and combinations thereof.   
     
     
         7 ) The method of providing a solenoid housing according to  claim 4 , wherein the step of providing a cup around said cylinder of malleable material is performed by a riveting method and further comprises the steps of:
 inserting said protrusion into said recess; and   compressing said protrusion in a direction towards the first part.   
     
     
         8 ) The method of providing a solenoid housing according to  claim 7 , further comprising the step of:
 providing said cylinder of malleable material with a non-magnetic region selected from the group consisting of:   a perforated region, an area comprised of non-magnetic material, a region wherein said region has a smaller cross-sectional area than a cross-sectional area of the remainder of the cylinder of malleable material, and combinations thereof.   
     
     
         9 ) The method of providing a solenoid housing according to  claim 1 , wherein a step of annealing the solenoid housing is performed following at least one of the following steps:
 providing a cylinder of malleable material having a first part and a second part, said first part having a first-part perimeter and said second part having a second-part perimeter;   reducing a size of the first-part perimeter to be less than a size of the second-part perimeter;   compressing at least a portion of said second part in a direction towards said first part to produce a flattened disk;   providing said cylinder of malleable material with a non-magnetic region; and   extending a bore from said first part toward said second part to at least a distance beyond said non-magnetic region.   
     
     
         10 ) The method of providing a solenoid housing according to  claim 8 , wherein the step of providing said cylinder of malleable material with said region wherein said region has a smaller cross-sectional area than a cross-sectional area of the remainder of said cylinder of malleable material further comprises the following step:
 reducing said cross-sectional area of said region to be approximately 10%-20% of said cross-sectional area of the remainder of the cylinder.   
     
     
         11 ) A solenoid housing comprising:
 a raised wall having a first end and a second end;   a center-piece having a first end and a second end;   a flattened disk at said second end of said raised wall and said second end of said center-piece; and   wherein said center-piece, flattened disk, and raised wall are formed of a one-piece construction.   
     
     
         12 ) The solenoid housing according to  claim 11 , wherein said center-piece includes a bore. 
     
     
         13 ) The solenoid housing according to  claim 11 , wherein said bore extends from said first end of said center-piece to a point between said first end and said second end of said center-piece. 
     
     
         14 ) The solenoid housing according to  claim 11 , wherein said raised wall includes a flange. 
     
     
         15 ) The solenoid housing according to  claim 14 , wherein said flange is generally perpendicular to said flattened disc. 
     
     
         16 ) A method of providing a solenoid housing, comprising the steps of:
 providing a solid cylinder of malleable material having a first part and a second part;   reducing a diameter of said first part of the cylinder to be less than a diameter of said second part of the cylinder;   compressing said second part in an axial direction toward said first part, resulting in a flattened disc;   cold forging an entire outermost perimeter of said flattened disc in a direction toward said first part for defining a first solid, raised wall;   extending said first part of the cylinder in a direction away from said second part of the cylinder for creating a center piece;   cold forging an entire outermost perimeter of the center piece for defining a second solid, raised wall;   extending the first solid, raised wall to define an annular recess having a depth; and   wherein the first part, second part, center-piece, first solid raised wall, and second solid raised wall are all integrally connected as a single piece.   
     
     
         17 ) The method of providing a solenoid housing according to  claim 16 , further comprising the step of:
 extending the second solid raised wall to define an annular recess having a depth.   
     
     
         18 ) The method of providing a solenoid housing according to  claim 16 , further comprising the step of:
 extending a bore in the center piece from a first end of said center-piece to a point between said first end and a second end of said center-piece.   
     
     
         19 ) The method of providing a solenoid housing according to  claim 16 , further comprising the step of:
 extending a third part of said cylinder away from said first part and said second part.   
     
     
         20 ) The method of providing a solenoid housing according to  claim 16 , further comprising the step of:
 extending a flange from said first solid raised wall.