Solenoid with an over-molded component

1. A solenoid ( 30 ), comprising:

a magnetic core ( 304 );

a pole piece ( 305 ) positioned substantially coaxially with the magnetic core ( 304 ) wherein the pole piece is a separate element from the magnetic core;

a movable armature ( 306 ) movable within the pole piece ( 305 ) between a first position and at least a second position;

a longitudinal groove ( 311 ) defined by the movable armature;

a gap (d 1 ) between the pole piece ( 305 ) and the movable armature ( 306 ) proximate a length of the longitudinal groove ( 311 ); and

an over-molded component ( 303 ) over-molded around at least a portion of the magnetic core ( 304 ) and at least a portion of the pole piece ( 305 ), wherein the over-molded component comprises a bobbin, and is further adapted to coaxially align and connect the magnetic core ( 304 ) and the pole piece ( 305 ) in a coaxial orientation.

2. The solenoid ( 30 ) of claim 1 , further comprising one or more grooves ( 410 , 411 ) formed in one or both of the magnetic core ( 304 ) and the pole piece ( 305 ) for receiving a portion of the over-molded component ( 303 ).

3. The solenoid ( 30 ) of claim 1 , further comprising a spacing ring ( 510 ) located at an interface between the magnetic core ( 304 ) and the pole piece ( 305 ).

4. The solenoid ( 30 ) of claim 3 , wherein the over-molded component ( 303 ) is over-molded around the spacing ring ( 510 ).

5. The solenoid ( 30 ) of claim 1 , wherein the movable armature ( 306 ) extends into at least a portion ( 313 ) of the magnetic core ( 304 ) in the second position.

6. The solenoid ( 30 ) of claim 1 , further comprising one or more grooves ( 311 ) that are a part of and wholly defined by the movable armature ( 306 ) for communicating a fluid between a first end and a second end of the movable armature ( 306 ).

7. The solenoid ( 30 ) of claim 1 , further comprising a protrusion ( 312 ) extending from and defined by the magnetic core ( 304 ).

8. The solenoid ( 30 ) of claim 1 , wherein the over-molded component ( 303 ) comprises a bobbin.

9. The solenoid ( 30 ) of claim 1 , further comprising a bobbin ( 703 ) located around at least a portion of the over-molded component ( 303 ).

10. A solenoid ( 30 ), comprising:

a magnetic core ( 304 );

a pole piece ( 305 ) positioned substantially coaxially with the magnetic core ( 304 ), wherein the pole piece is a separate element from the magnetic core;

a movable armature ( 306 ) movable within the pole piece ( 305 ) between a first position and at least a second position;

a longitudinal groove ( 311 ) defined by the movable armature ( 306 );

a gap (d 1 ) between the pole piece ( 305 ) and the movable armature ( 306 ) proximate a length of the longitudinal groove ( 311 );

an over-molded component ( 303 ) overmolded around at least a portion of the magnetic core ( 304 ) and at least a portion of the pole piece ( 305 ) wherein the over-molded component is adapted to coaxially align and connect the magnetic core ( 304 ) and the pole piece ( 305 ) in a coaxial position, wherein the over-molded component further comprises a bobbin;

a plurality of grooves defined by the magnetic core ( 304 ) configured to secure the over-molded component ( 303 ) thereto; and

a plurality of grooves defined by the pole piece ( 305 ) configured to secure the over-molded component ( 303 ) thereto.

11. The solenoid ( 30 ) of claim 10 , further comprising one or more grooves ( 410 , 411 ) formed in one or both of the magnetic core ( 304 ) and the pole piece ( 305 ) for receiving a portion of the over-molded component ( 303 ).

12. The solenoid ( 30 ) of claim 10 , further comprising one or more grooves ( 311 ) that are a part of and wholly defined by the movable armature ( 306 ) for communicating a fluid between a first end and a second end of the movable armature ( 306 ).

13. The solenoid ( 30 ) of claim 10 , further comprising a protrusion ( 312 ) extending from and defined by the magnetic core ( 304 ).