Idle air control valve

1. A control valve assembly comprising:

a plastic housing;

an electric actuator disposed within the housing; and

a plastic electrical connector joined to an axially facing surface of the housing to form a seal between an axially facing surface of the electrical connector and the axially facing surface of the housing, the electrical connector including a plurality of electrical contacts communicating with the electric actuator and a flange extending outward from the electric connector for securing the control valve assembly in place and a circumferential lip that engages a radially inner surface of the housing, wherein a joint is formed between the axially facing surface of the plastic housing and the axially facing surface of the electrical connector, the joint defining the seal between the axially facing surface of the electrical connector and the axially facing surface of the plastic housing that extends to a radially outermost surface of the housing.

2. The assembly as recited in claim 1 , including a seal disposed on an outer surface of the connector for preventing blow by past the control valve.

3. The assembly as recited in claim 1 , wherein the flange comprises a planar portion extending radially outward from the electrical connector.

4. The assembly as recited in claim 3 , wherein the flange extends partially about an outer circumference of the electrical connector.

5. The assembly as recited in claim 1 , wherein the flange includes a notch for partially receiving a fastening member.

6. The assembly as recited in claim 1 , wherein the housing comprises a plurality of ribs extending from an outer surface for centering the valve assembly within a bore.

7. The assembly as recited in claim 6 , wherein the ribs include a length in an axial direction and are spaced apart about an outer periphery of the housing.

8. The assembly as recited in claim 6 , wherein the plurality of electrical contacts comprise a first plurality of electrical contacts disposed within a hood, and a second plurality of electrical contacts in electrical contact with the first plurality of electrical contacts and extending outwardly from the connector into electrical contact with the electric actuator.

9. The assembly as recited in claim 1 , wherein the electrical connector comprises a plastic material and the plurality of electrical contacts are at least partially molded within the plastic material.

10. The assembly as recited in claim 9 , including an ultrasonic weld joining the electrical connector to the housing at the joint.

11. An idle air control valve assembly comprising:

a plastic sleeve defining an inner space;

an electric actuator mounted within the sleeve; and

a plastic electrical connector welded to a radially inner surface of the sleeve to enclose the electric actuator within the inner space and form a seal between the radially inner surface of the sleeve and radially outer surface of the electrical connector, the electrical connector including a plurality of terminals in communication with the electric actuator and a mounting flange disposed at least partially about an outer surface of the electrical connector, wherein a joint is defined between the plastic electrical connector and the plastic sleeve, the joint comprising a welded interface between the radially inner surface of the plastic sleeve and the radially outer surface of the plastic electrical connector and axially facing surfaces of the sleeve and the connector to form a seal that extends to a radially outermost surface of the sleeve.

12. The assembly as recited in claim 11 , including an actuating member movable along an axis by the electric actuator.

13. The assembly as recited in claim 12 , wherein the mounting flange extends radially outward from the electrical connector transverse to the axis.

14. The assembly as recited in claim 13 , wherein the flange includes a notch for partially receiving a fastening member and for defining a radial location of the control valve assembly.

15. The assembly as recited in claim 11 , wherein the plastic sleeve includes a plurality of ribs having an axial length and extending radially outward form the plastic sleeve for centering the valve assembly within a bore.

16. The assembly as recited in claim 15 , wherein the ribs are spaced apart from each other about the outer periphery of the plastic sleeve.

17. The assembly as recited in claim 11 , wherein the sleeve and electrical connector are ultrasonically welded together at the joint.