Control valve having a metal sleeve within a plastic valve body

1. A method of manufacturing a control valve, the control valve including a valve body having a plastic body housing defining an inner bore and a metallic sleeve defining a first annular projection and a second annular projection, a spool, a coupler in the form of a pole piece and having a sleeve projection, and an actuator, the method comprising:

press fitting the metallic sleeve into the body housing such that the first annular projection and the second annular projection seal against the inner bore via a diameter of the first annular projection and the second annular projection being larger than the inner bore;

inserting the spool into the metallic sleeve, wherein the spool includes a first land and a second land, and wherein the first annular projection and the second annular projection are positioned along the metallic sleeve such that the first land and the second land do not come into contact with inner valve bores adjacent to where the first annular projection and the second annular projection are located while the spool is positioned at any of a first position, a second position, and a position between the first position and the second position;

inserting the sleeve projection into the metallic sleeve;

coupling the pole piece to the sleeve, wherein an end of the spool is at least partially received in the sleeve projection in one of the first position and the second position, and wherein the sleeve projection includes an inner tapered portion that is arranged along an inner surface of the sleeve projection and configured to receive the end of the spool in the one of the first position and the second position; and

coupling the actuator to the coupler and the valve body.

2. A control valve comprising:

a valve body including a plastic body housing defining an inner bore and a metallic sleeve arranged within the inner bore of the body housing, wherein the metallic sleeve includes a first annular projection and a second annular projection each defining a diameter larger than the inner bore to form a press fit between each of the first annular projection and the second annular projection and the inner bore;

a spool received within the metallic sleeve and movable between a first position and a second position, wherein the spool includes a first land and a second land, and wherein the first annular projection and the second annular projection are positioned along the metallic sleeve such that the first land and the second land do not come into contact with inner valve bores adjacent to where the first annular projection and the second annular projection are located while the spool is positioned at any of the first position, the second position, and a position between the first position and the second position;

an actuator coupled to the valve body and coupled to the spool; and

a pole piece arrange between the actuator and the valve body and including a sleeve projection within which an end of the spool is at least partially received in one of the first position and the second position, wherein the sleeve projection includes a outer tapered portion and an inner tapered portion, the outer tapered portion being arranged along an outer surface of the sleeve projection at an axial end of the sleeve projection, and the inner tapered portion being arranged along an inner surface of the sleeve projection and configured to receive the end of the spool in the one of the first position and the second position.

3. The control valve of claim 2 , wherein the body housing includes a first housing port and a second housing port,

wherein the metallic sleeve includes a first sleeve port in fluid communication with the first housing port and a second sleeve port in fluid communication with the second housing port, and

wherein the spool inhibits fluid communication between the first sleeve port and the second sleeve port when in the first position, and provides communication between the first sleeve port and the second sleeve port when in the second position.

4. The control valve of claim 3 , wherein the first annular projection is in a press fit engagement with the inner bore of the plastic body housing between the first housing port and the actuator, and the second annular projection is in a press fit engagement with the inner bore of the plastic body housing between the first housing port and the second housing port.

5. The control valve of claim 2 , wherein the metallic sleeve defines a sleeve length, and

wherein the inner bore defines a bore length that is less than the metallic sleeve length.

6. The control valve of claim 2 , wherein the metallic sleeve is formed of a hard anodized aluminum.

7. The control valve of claim 2 , wherein the metallic sleeve is formed of a ferrous metal.

8. The control valve of claim 2 , wherein the sleeve projection is sized to be received within the metallic sleeve.

9. The control valve of claim 8 , wherein the pole piece includes a coupling flange sealingly engaged with the metallic sleeve.

10. The control valve of claim 9 , wherein a gap is defined between a flange surface of the plastic body housing and the coupling flange to maintain the metallic sleeve in compression between the pole piece and the plastic body housing.

11. A valve body for a control valve that includes an actuator configured to move a spool within the valve body, and a coupler arranged between the actuator and the valve body, the valve body comprising:

a plastic body housing defining an inner bore, a first housing port, and a second housing port; and

a substantially cylindrical metallic sleeve press fit into the inner bore and configured to receive the spool, wherein the metallic sleeve defines a first sleeve port in fluid communication with the first housing port, and a second sleeve port in fluid communication with the second housing port, wherein the metallic sleeve includes a first annular projection and a second annular projection each defining a diameter larger than the inner bore to form a seal between each of the first annular projection and the second annular projection and the inner bore,

wherein the spool includes a first land and a second land, and wherein the first annular projection and the second annular projection are positioned along the metallic sleeve such that the first land and the second land do not come into contact with inner valve bores adjacent to where the first annular projection and the second annular projection are located while the spool is positioned at any of the first position, the second position, and a position between the first position and the second position; and

a pole piece coupled to the metallic sleeve and including a sleeve projection within which an end of the spool is at least partially received in one of the first position and the second position, wherein the sleeve projection includes an inner tapered portion that is arranged along an inner surface of the sleeve projection and configured to receive the end of the spool in the one of the first position and the second position.

12. The valve body of claim 11 , wherein the metallic sleeve is formed of hard anodized aluminum.

13. The control valve of claim 11 , wherein the metallic sleeve is formed of a ferrous metal.

14. The valve body of claim 11 , wherein the seal against the inner bore formed by the first annular projection is arranged between the first housing port and the second housing port.

15. The valve body of claim 11 , wherein the inner bore defines an inner bore length, and the metallic sleeve defines a sleeve length that is longer than the inner bore length.