Miniature high performance solenoid valve

1. A solenoid valve assembly comprising:

an armature having a longitudinal axis, the armature being moveable along the longitudinal axis from a first position to a second position; and

a bobbin including a solenoid coil configured to electromagnetically move the armature along the longitudinal axis from the first position to the second position when energized;

wherein the armature has an ovular transverse cross section;

the solenoid valve assembly further comprising a flux coupler and a flux bracket, wherein a magnetic circuit to electromagnetically move the armature comprises the flux coupler, the flux bracket, and the armature;

wherein the flux bracket has a pole piece that limits the movement of the armature along the longitudinal axis, thereby determining a stroke length of the armature; and

wherein one of the flux coupler or flux bracket includes a plurality of ridges and the other includes a plurality of slots, wherein the flux coupler and flux bracket are slidably moveable relative to each other to adjust the position of the pole piece.

2. The solenoid valve assembly of claim 1 , wherein the ovular transverse cross section of the armature has an aspect ratio of greater than 3:1.

3. The solenoid valve assembly of claim 1 , wherein the bobbin includes one or more spring clips that are preloaded to secure positioning of the bobbin within the solenoid valve assembly.

4. The solenoid valve assembly of claim 1 , wherein the pole piece has an ovular cross section commensurate with the ovular cross section of the armature.

5. The solenoid valve assembly of claim 1 , further comprising a cover assembly configured to provide ingress protection for electrical connections that energize the solenoid valve assembly, wherein the cover assembly comprises a connector that houses the electrical connections and a rubber boot that fits over the connector.

6. The solenoid valve assembly of claim 1 , wherein the solenoid valve assembly has a width in a direction perpendicular to the longitudinal axis of 9 mm or less.

7. The solenoid valve assembly of claim 1 , further comprising a plurality of alignment pins that provide for proper alignment of valve ports with cooperating ports on a manifold.

8. The solenoid valve assembly of claim 1 , wherein the bobbin defines a recess having an ovular cross section for receiving the armature and restricting lateral movement of the armature, thereby providing a linear actuation path for the armature along the longitudinal axis.

9. The solenoid valve assembly of claim 8 , wherein the recess of the bobbin includes a plurality guiding ribs configured to provide an area for shed material to accumulate away from the armature.

10. The solenoid valve assembly of claim 1 , further comprising a diaphragm, wherein when the armature moves from the first position to the second position, the diaphragm moves between a first diaphragm position and a second diaphragm position.

11. The solenoid valve assembly of claim 10 , further comprising a first spring and a second spring;

wherein when the armature is in the first position, the first spring biases the armature against the diaphragm to render the solenoid valve assembly in an OFF position, and when the valve assembly is energized and the armature is in the second position, the second spring moves the diaphragm to render the solenoid valve assembly in an ON position.

12. The solenoid valve assembly of claim 11 , further comprising a spring rest that receives the first spring, wherein the armature has barbs into which the spring rest is pressed, and the position of the spring rest is adjustable based upon where the spring rest is pressed into the barbs of the armature.

13. The solenoid valve assembly of claim 10 , wherein the diaphragm is a rocker comprising a rocker insert that is over molded with a seal component.

14. The solenoid valve assembly of claim 13 , the rocker rocks about a through hole, and the rocker has recess pockets that prevent rubber flash from entering the through hole.

15. The solenoid valve assembly of claim 13 , further comprising a normally open port, a normally closed port, and a common port;

wherein in the first diaphragm position, the seal component seals the normally closed port and the normally open port is open, and in the second diaphragm position, the seal component seals the normally open port and the normally closed port is open; and,

in the second diaphragm position, the normally closed port and the common port are in fluid communication to permit a flow of a fluid through the valve assembly.

16. A method of setting a stroke length of a solenoid actuator valve assembly comprising the steps of:

displacing a pole piece of the valve assembly sufficient to achieve optimal valve performance, the optimal valve performance corresponding to a minimum stroke length needed to achieve maximum flow through the valve; and

fixing a position of the pole piece within the valve assembly;

wherein the solenoid actuator valve assembly has a flux coupler and a flux bracket including the pole piece, and one of the flux coupler or flux bracket includes a plurality of ridges and the other includes a plurality of slots,

the setting method further comprising slidably moving the flux coupler and flux bracket relative to each other via the ridges and slots to set the position of the pole piece at which the pole piece is fixed within the valve assembly.