CA1095219A - Bobbin and method of making terminated bobbin coil - Google Patents

Bobbin and method of making terminated bobbin coil

Info

Publication number
CA1095219A
CA1095219A CA319,384A CA319384A CA1095219A CA 1095219 A CA1095219 A CA 1095219A CA 319384 A CA319384 A CA 319384A CA 1095219 A CA1095219 A CA 1095219A
Authority
CA
Canada
Prior art keywords
bobbin
wire
post
coil
forming portion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA319,384A
Other languages
French (fr)
Inventor
Charles E. Reynolds
Donald W.K. Hughes
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TE Connectivity Corp
Original Assignee
AMP Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AMP Inc filed Critical AMP Inc
Application granted granted Critical
Publication of CA1095219A publication Critical patent/CA1095219A/en
Expired legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/10Connecting leads to windings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00Coils
    • H01F5/04Arrangements of electric connections to coils, e.g. leads
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/4902Electromagnet, transformer or inductor
    • Y10T29/49071Electromagnet, transformer or inductor by winding or coiling

Abstract

ABSTRACT
In a method of making a terminated coil on a bobbin moulded with severable posts adjacent terminal receiving cavities at one end of a coil forming portion, the coil wire is wrapped around the posts and the wire is located to extend across the terminal receiving cavities. Insertion of terminals into respective cavities together with movement of a cutting blade against the posts both severs the wire and posts and terminates the wire.

Description

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The invention relates to a method o makin~ a terminated coil on a bobbin and to bobbins for use in the method~ .
In a known method of making a terminated coil on a bobbin, the coil wira is wound around a post extending from the bobbin adjacent an end of a coil forming portion of the ~obbin and around the coil forming portion.
A di~advantage of the known method ls that the po~t ~s a metal terminal post and a subsequent soldering step is required to secure the wire to the post.
Terminals are known which can be urged a~ainst the wires to es ablish electrical connection thereto without - the need of a subsequent soldexing step but it is desirable to use such terminals in conjunction with conventional coil winding machinery.
According to one aspect of the inventlon~ a method ~ of making a terminated coil comprises the steps of locatlng the wire to ext.end across a terminal receivin~
cavity provided in the bobbin ad~acent ~he post, winding a predetermined number of turns of wire around the coil forl~.ing portion of the bobbin, inserting a terminal into ~he cavity and moving a cutting means against the post thereby to cut the wire extendi.ng around the post and electrically to connect th~ wlre and ~he terminal, The terminal may anchor in the cavity ~nd desirably the post may be removed b~ the cutting means during the w~r severing stroke~ The provisioll of th post inte~ral 5~

with the bobbin and the method of the invention en~ble the use of suitable conventional coil windin~ machinexy.
According to another aspect of the i~vention, a bobbin for use in the method is moulded from plastics material and comprises a coil forming portion, at leas~
one post formed on the bobbin adjacent an end of the coil forming portion a~d a terminal rec~lving cavity provided ln the bobbin adjacent the or each post~
Examples of the ~nvention will now b~ described with reference to the accompanying drawings in which:
Figure 1 is a perspective view of a first example of bobbi~ according to the invention;
Figure 2 is a similar view to Figure l but showing a coil wire wound on the bobbin prior to a termination and cutting step;
Figure 3 is a similar vie~J to Figure 2 after the tenmination and cutting step;
Figure 4 is a perspec~ive view o part of a secon~
example of bobbin with a coil wire wound thereon and prior to a termination and cutting stepj Figures 5 to 7 are diagrammatic views i.llustrating successive stages in winding coil wire on bobbins of Figure 4 using a known coil winding machine;
Flgure 8 is a perspective view of part of a second ex~mple of bobbin with a coil wlre wo~nd thereon and prior to a termination or cutting stepi and, Figure 9 is a perspective view of a thlrd example of .... .

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bobbin with a coil wire wound thereon and prior to a termination or cutting step~
The bobbln 10 shown in Figures 1 to 3 is moulded in ~ne piece of plastics material and comprises a tubular coil forming portion 11 at opposite axial ends o~ which extend transverse retaining flanges 12 and 13, xespectively.
A substantially rectangular block 14 is moulded on an upper side of flange 13 and provided with a pair of open-topped ~erminal rec~iving cavities 15 and 16 located in side-by-side relation. Inner and outer faces o~ the block 17 and 18 respectively, constituti~g the transverse walls of the cavities, are provided with pairs of wire re~eiving slots 19 and 20 communicating with ~he cavities, the slots 19 being aligned with respective slots ~0.
A pair of severable posts 21 and 22 respecti~ely, are moulded on the outer face and extend axially away from the core forming portion a~ locations adjacent a lower end of each slot 200 A terminal 23 for use with the bobbin comprises a contact portion 24 extending from a wire connecting ferrule 25. The contact portion 24 comprises a reversel~
bent web orming a spring 26 having insulation penetrating serrations 27 on one ace and anchoring tan~s 28 extending from opposite side edges. The terminal is generall~
similax to that described in US Patent Specification Ai`. 4~026,013.
In the first example of the method, a coil wire i5 }

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initially ~Jound around post 21, located in one pair of the aligned slots 19 and 20 located to extend across cavity 15, wound around the coil forming portion 3.1, ~ocated in the other aligned 51QtS 19 and 20 to exkend across cavity 16 and finally wrapped around post 22 as indicated by the arrows in Figure 1. Terminals 23 ar~
driven into respective cavities and a cutting blade 30 moved against the posts 21 and 22 preferably in the same .stroke to cut the wire wrapped therearound and preferably to remove the posts. As the terminals are driven into e cavities, the serrations penetrate the thin varnish-like insulation on the wire and establish electrical connection thereto and ~le tangs 28 bight into the cavity wall securely to anchor the terminals in the cavityq The terminals may be inserted into the cavities by using a machine similar to that described in US Patent 4,099,316.
. The winding operation may be performed by a suitable conventional winding machine.
Th~ second exc~mple of bobbin (Fi~ure 4~.is desiglled ~or use with a known coil winding machinery indicated in Figures 5 to 7. In this ex~mple, posts 31r3~ extend transversely of the axis of the cQil for~ing p~rtion 33 from ~nd faces o~ a rectangular block 34 on flange 35.
A wire admitting recess 36, opening towards the core forminy portion 33, is formed a-t a central location a-t the . . top of the block and wire guiding posts 38 upstand from the top of the block on opposite transverse ends of the.
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rec~ss. The recess co~unicates with wixe receiving slots 39 formed in respective adjacen~ walls o~ terminal receiving cavities 40 provided in the block which slots are aligned with respective wire receiving slo~s 41 formed in the remote walls o~ the cavities so that a coil wire can extend ~xom the coil forming portion into the recess 36, around the posts 38, and across the cavities 40~ located in the slots 39 and 41, and around posts 31.
The winding machine comprisPs a central suppcr~ 45 which can be rotated in the plane of the paper through an angle of 180 degrees about axis 46. Coil support arms 47 extend from opposite ends of the support 45 one being losated at a bobbin loading station 48.while the . other arm is located at the windiny station 49. A wire guiding arm 51 is provided at the winding station and has wire guide means 52 at its end for guiding the wire from a supply, such as a reelO to a bobbin 58 held on ~he arm 57. Machines of this type al50 have a winding mandrel 59 movable from the retracted position oE Figure 5 into t~e central opening in a bobbin of the arm 47 alld rotatable/ as shown in Figure 6f to wind the wire on the bobbin while the arm 51 moves to and fro to distribute the windings evenly along the coil. forming portion.
In use~ starting with the parts in the position of Flgure 5 wlth the wire wrapped around the post 3~ at the winding station, the mandrel 59 first ~oves into the opening in ~he bobbin as shown in Figure 6~ Thereafter~
.

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~he mandrel rotates through 90 degress so that the upper surface of the block is below the end of the traversing arm 51 which then describes a path laying the wire in slot 41 and 39 across the cavity 40, and around a post 38 Thereafter the mandrel rotates at a relatively high speed while the arm 5} traverses o wind the coil on the bobbin~
Subsequently, the mandrel is stopped ~lith the upper surface of the block below the arm 51 which lays the wire .across ca~rity 40 and in the other slot 39 and 417 The m~ndrel again rotates through 90 degrees so that the post 31 is below ~he arm 51 which wraps the ~ire around the po5t as shown in Figure 7.
The support 45 i5 then rotated through 180 degrees . to provlde an unwound bobbin at the winding station 49 and deliver the wound bobbin to the loading station 48.
The operator cuts the wire adjacent to the post 31 or the wound bo~bin and removes the bobbin from the arm 47.
The terminal inserting and cutting operations described above can be carried out at a subsequent work station or 20 they can be carried out by mechanisms provided at the loading station 48, if desired.
Previously, machines of this type ha~7e been used to wind coil5 or bobbins having metal terminal posts instead o~ the integral plastics binding posts of the bobbins o~
25 ~he invention which can now be. substituted f or the previous . . bobbins without extensive modification of the wind~ng machine. The soldering step pre~iously required can .. . . ~ :. ; ; ~ ~;
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2~

~herefore readily be replaced by the termlnal lnsertion step and wire cutting step of the present invention.
The third example o bobbin is modiied in that, a post 62 which extends from the block 61 at one end of the coil forming portion has an axially extending portion 63 and an upstanding free end 64 provided with oppositely facing wire stabilising shoulders 65 and 66. The winding and terminating operations are similar to these described above with removal of the post 62 duriny termination.
~ fourth example OL bobbin 67, ~ho~m in Figure 9, is designed to permit tap connections to the coil winding~
~o pairs of terminal recelving cavities 69 are provided on opposite sides of the ~lanye 68 and the cavities have associated posts 70 and 71, respectively. The winding and termination steps are similar to these described above~
The bob~ins and method of the invention are suitable for use with slotted plate terminals as described in US 3~979~615 and the profiles o~ the terminal recelving cavities can be modified accordingly.

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Claims (6)

The embodiments of the invention for which an exclusive property or privilege is claimed are as follows:
1. A method of making a terminated coil comprising the steps of winding the coil wire around a post formed on a bobbin adjacent an end of a coil forming portion of the bobbin, locating the wire to extend across a terminal receiving cavity provided in the bobbin adjacent the post, winding a predetermined number of turns of wire around the coil forming portion of the bobbin, inserting a terminal into the cavity and moving a cutting means against the post thereby to cut the wire extending around the post and electrically to connect the wire and the terminal.
2. A method according to claim 1 including the steps of locating the wire to extend across a second terminal receiving cavity provided in the bobbin adjacent a second post formed on the bobbin adjacent an end of the coil forming portion of the bobbin after winding the wire around the coil forming portion of the bobbin, inserting a second terminal into the second cavity and moving the cutting means against the second post thereby to cut the wire extending around the second post and electrically to connect both ends of the wire to respective terminals.
3. A method according to claim 2 including the steps of returning the wire to extend across the second cavity and winding an additional number of turns of wire around the coil forming portion of the bobbin after winding the wire around the second post and prior to cutting, locating the wire to extend across a third terminal receiving cavity provided in the bobbin adjacent a third post formed in the bobbin adjacent an end of a coil forming portion of the bobbin and winding the wire around the third post, inserting a third terminal into the third cavity and moving the cutting means against the third post thereby to cut the wire extending around the third post and electrically to connect the wire and the third terminal.
4. A method according to claim l or claim 2 in which the or each post is severed from the bobbin by the wire cutting stroke of the cutting means.
5. A method according to claim 3 in which each post is severed from the bobbin by a wire cutting stroke of the cutting means.
6. A bobbin for use in the method according to claim 1 which bobbin is moulded from plastics material and comprises a coil forming portion, at least one post formed on the bobbin adjacent an end of the coil forming portion and a terminal receiving cavity provided in the bobbin adjacent the or each post.
CA319,384A 1978-02-03 1979-01-10 Bobbin and method of making terminated bobbin coil Expired CA1095219A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US05/874,958 US4166265A (en) 1978-02-03 1978-02-03 Coil bobbins and termination of coil windings
US874,958 1978-02-03

Publications (1)

Publication Number Publication Date
CA1095219A true CA1095219A (en) 1981-02-10

Family

ID=25364961

Family Applications (1)

Application Number Title Priority Date Filing Date
CA319,384A Expired CA1095219A (en) 1978-02-03 1979-01-10 Bobbin and method of making terminated bobbin coil

Country Status (7)

Country Link
US (1) US4166265A (en)
EP (1) EP0003647B1 (en)
JP (1) JPS54152123A (en)
BR (1) BR7900571A (en)
CA (1) CA1095219A (en)
DE (1) DE2960953D1 (en)
ES (1) ES477402A1 (en)

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Also Published As

Publication number Publication date
ES477402A1 (en) 1980-04-01
EP0003647A1 (en) 1979-08-22
JPS6233730B2 (en) 1987-07-22
EP0003647B1 (en) 1981-10-14
BR7900571A (en) 1979-08-28
JPS54152123A (en) 1979-11-30
US4166265A (en) 1979-08-28
DE2960953D1 (en) 1981-12-24

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