AU2003205309A1 - Inductive device - Google Patents

Description

INDUCTIVE DEVICE

Related Application

This application is a continuation-in-part of Serial No. 10/057248, filed January 25, 2002.

Background ofthe Invention

This invention relates generally to inductive devices, and more particularly to coils of fine wire and of very small dimensions suitable for use in hearing aids and other devices employing miniature circuitry.

In certain applications, such devices are referred to as telecoils and are installed in a hearing aid to sense the magnetic field of a telephone or other assistive listening system for the hearing impaired. The detection of such fields controls the operation of the electronic circuit ofthe hearing aid. In current practice, a telecoil typically consists of several thousand turns of fine insulated coil wire, typically on the order of one thousandth inch in diameter, wound on a ferrous or other core of magnetic material. In manufacture, the winding wire may be wound directly on a bobbin of magnetic material which forms a part ofthe telecoil, or the wire may be wound on a mandrel which is removed after winding, leaving a hollow core into which a ferrous rod is later inserted. The ultrafine coil wire is very fragile and is typically unsuited for connection to external circuit components for that reason. Therefore, it is typically necessary to provide heavier connection or lead wires that extend to such external circuit elements, the lead wires having, for example, five or six times greater diameter and being soldered or otherwise electrically connected to the ends ofthe fine winding wire. In these miniature devices terminal pads may be provided at one or both ends ofthe coil or cemented to the exterior body ofthe coil, and the fine wire may be wrapped around the lead wires which are in turn attached by adhesive or otherwise to the outside ofthe coil after winding. One ofthe objects ofthe invention is to provide improved coils of minimized diameter and overall coil length. Another object is to provide an improved structure whereby the lead wires are pre-mounted on the bobbin (or mandrel) prior to winding, thus providing to the winding equipment integral posts for coil wire terminations. Another object is to provide an improved structure in which neither solder connections nor bare lead wires come into contact with the ultrafine coil wire ofthe winding.

Another object is to provide an improved construction that eliminates mechanical stress on the solder connections and increases the pull strength ofthe lead wires when connecting them to external circuit elements.

Another object is to provide a construction in which the lead or connection wires will only be subjected to bending in an area remote from the soldered area during connection ofthe coil to external circuit elements, as the soldered area typically becomes embrittled and weakened during soldering.

Another object is to provide the foregoing advantages to the coil using conventional winding methods but at reduced costs for parts, tooling and assembly.

Other objects ofthe invention will be understood from the following detailed description with reference to the appended drawings.

Brief Summary ofthe Invention

With the foregoing objects in view, this invention features lead wires that extend inwardly ofthe coil winding from end to end thereof, forming start and finish connection posts at one end ofthe coil around which the respective ends ofthe winding wire are wound. Advantageously, the lead wires are preformed and the coil winding is wound over the lead wires, the ends ofthe winding being extended out to the posts for winding on and electrical connection to the posts.

Another feature is that the foregoing construction can be achieved either by winding the fine coil wire on a bobbin of magnetic material that forms a part ofthe completed coil, or the fine wire may be wound on a removable mandrel which, after winding, is replaced by a ferrous or other magnetic core or rod.

Another feature is that the improved coil may be formed on any of several presently available winding machines in which the bobbin or mandrel is either rotating or non-rotating. Other features ofthe invention and the achievement of other objects hereinabove referred to will be evident from the following description. Drawing

Fig. 1 is a side elevation of a first embodiment of coil bobbin for winding the coil ofthe invention.

Fig. 2 is a view in plan ofthe bobbin of Fig. 1. Fig. 3 is a right end elevation on line 3-3 of Fig. 1.

Fig. 4 is an end elevation corresponding to Fig. 3 and illustrating an alternative embodiment ofthe bobbin.

Fig. 5 is an axial elevation of an assembly having a coil wound on the bobbin of Figs. 1 to 3. Fig. 6 is an elevation taken on line 6-6 of Fig. 5.

Fig. 7 is an end elevation on line 7-7 of Fig. 5.

Fig. 8 is an elevation corresponding to Fig. 7 and illustrating the alternative embodiment of Fig. 4.

Fig. 9 is a schematic drawing of a conventional flying head multi-axis coil winding machine suitable for forming coils according to the invention.

Fig. 10 is a schematic drawing of a rotating chuck winding machine suitable for winding coils according to the invention.

Fig. 11 is a view in perspective of a second embodiment of coil bobbin for winding the coil ofthe invention. Fig. 12 is a front elevation ofthe embodiment of Fig. 1 1.

Fig. 13 is a right side elevation taken on line 13-13 of Fig. 12.

Fig. 14 is an end elevation taken on line 14-14 of Fig. 12.

Detailed Description Referring to Figs. 5-7, a coil 10 comprises a winding 12 of several thousand turns of ultrafine wire closely compacted and extending between ends 14 and 16 ofthe coil. The turns ofthe winding are spaced from a longitudinal axis a-a ofthe coil, and a pair of lead wires 18 and 20 extend axially from end to end ofthe coil through the space so provided. At the end 14 ofthe coil the lead wires 18 and 20 extend a sufficient distance for connection to the external circuitry of a hearing aid or other device (not shown). At the end 16 ofthe coil the lead wires are formed and separated to extend axially away from the coil, forming a start post 22 and a finish post 24. Ends 26 and 28 ofthe wire of the winding 12 are respectively wrapped on the posts 22 and 24, and soldered or welded thereto.

Figs. 1 to 3 illustrate a first alternative form of bobbin 30 over which the turns of the winding 12 may be formed. The bobbin 30 is formed of two identical pieces 32 of ferrous or other magnetic material blanked from a flat sheet. Each ofthe pieces 32 is formed with dimples 34, then cut into elongate strips and formed with ends 36 extending normal to the axis a-a. Two ofthe pieces so formed are placed with their dimples 34 in mutual contact, providing a space 38 between the pieces 32 extending longitudinally of the bobbin 30. The dimples 34 are then welded to form a rigid structure. Other conventional steps of fabrication such as tumbling, annealing and coating may also be performed on the bobbin in preparation for winding the fine wire thereon.

The lead wires 18 and 20, preferably preformed to provide the terminal posts 22 and 24, are extended through the space 38 from end to end ofthe bobbin 30 in preparation for forming the winding 12 thereon between the ends 36 ofthe bobbin. If desired, the ends 36 ofthe bobbin may be replaced by ends 40 of more extended area as illustrated by the alternative embodiment of Figs. 4 and 8. The bobbin ends 40 are preferably shaped to extend only minimally or not at all beyond the diameter ofthe winding 12 ofthe coil 10. The ends 40 serve for further confinement ofthe ends 14 and 16 ofthe coil 10 during and after the winding operation.

Fig. 9 illustrates the winding ofthe coil ofthe invention on a conventional flying head multi-axis winding machine. The fine wire 42 is drawn from a supply spool 44 over an adjustable tensioning device 46, through a hollow tube wire guide 48, and downwardly through a depending tubular portion 50 thereof. The bobbin 30 is fastened to a chuck 32. The wire guide 48 is the so-called flying head type, being adapted for rotation as indicated by an arrow b about an axis c to form the turns ofthe winding 12 around the stationery bobbin 30, or alternatively for rotation around either ofthe respective axes ofthe start and finish posts 22 and 24 to wrap the ends ofthe winding wire 12 thereon. The winding operation begins with the winding ofthe wire 42 on the start post 22, after which the wire is directed to the space between the ends 14 and 16 ofthe spool, the axis of rotation ofthe guide 48 reverting to the axis c-c. Rotation about the axis c-c then begins. As the rotation continues, the wire guide 48 reciprocates vertically as indicated by arrows 52 to distribute the turns ofthe winding uniformly between the ends 14 and 16 ofthe coil. Finally, the rotational axis is again shifted to wrap the end ofthe wire 42 on the finish post 24.

Fig. 10 illustrates a conventional rotating chuck winding machine having a chuck 54 rotated by a motor 56. Winding wire 58 is fed from a supply spool 60 over an adjustable tensioning device 62 to a traversing wire guide 64 which moves reciprocally between limits 66 and 68 to distribute the turns ofthe winding uniformly between the ends 14 and 16 ofthe coil 10.

In operation, an end ofthe wire 58 is first wrapped on the start post 22 either manually or in any other convenient manner, then fed to the space between the ends 14 and 16 ofthe bobbin for winding the body ofthe coil. Finally, the wire is led to the finish post 24 and manually or otherwise wrapped thereon. In accordance with conventional practice, a controller 70 coordinates the speed of rotation ofthe motor 56 and the reciprocal movement ofthe guide 64 for controlling the formation ofthe coil 10. In either ofthe winding machines of Figs. 9 and 10, in place ofthe bobbin 30 a removable mandrel of suitable form may be placed in the chuck 20 or 54. The mandrel can be formed to accept the lead wires 18 and 20 with the start and finish posts 20 preformed thereon prior to formation ofthe winding 12. In that case, the mandrel is provided with longitudinally extending slots to accept the lead wires. After completion ofthe winding including attachment of an end thereof to the finish post 24, the mandrel 28 is removed from the chuck and withdrawn from the coil. A core of ferrous or other magnetic material is then inserted through the coil to complete the inductive device. Alternatively, the lead wires can be mounted in longitudinal slots of a suitable core and the assembly inserted into the coil after forming the winding and withdrawing the mandrel. In the illustrated embodiments, both ofthe lead wires 18 and 20 are preformed at the end 16 ofthe coil 10 with two right angle bends to form radially extending portions thereof for mutually spacing the posts 22 and 24. Alternatively, only one ofthe lead wires may be bent in this fashion. In either case, the posts 22 and 24 extend in the axial direction ofthe coil 10 for wrapping the ends ofthe winding 12 thereon. In a subsequent operation the posts 22 and 24 are advantageously located for automated dip-soldering of the connections to the wires 26 and 28 ofthe winding without refixturing ofthe coil. After the soldering operation the posts 22 and 24 are trimmed to a suitable length if necessary and then preferably bent back against the ends 14 and 16 ofthe coil to minimize its overall length.

Other embodiments may be substituted for that ofthe bobbin 30, if desired. Advantageously, the one-piece alternative bobbin 72 of Figs. 11 to 14 may be employed. The bobbin 72 is blanked from a flat sheet of ferrous or other magnetic material to form integral elongate portions 74 and 76 joined by an integral elongate connecting portion 78. Each ofthe portions 74 and 76 is formed with ends 80 similar in form and function to the bobbin ends 36 in Figs. 1 to 8. The blank so formed is then folded by bending the connecting portion 78 longitudinally to create an elongate space 82 between the portions 74 and 76, similar in function to the space 38 of Figs. 1 to 8.

The foregoing description with reference to the winding ofthe bobbin 30 is fully applicable to the bobbin 72. In addition, the bobbin 72 provides other advantages. Its fabrication, employing fewer parts and fewer steps of fabrication, may be easier and less costly to produce, particularly with regard to alignment of parts and the elimination of welding time and equipment. The bobbin 72 is strong and durable in the form illustrated. With the connecting portion 78 extending the full length ofthe coil winding between the ends 80, it increases the core cross-section and thereby improves the magnetic performance ofthe coil. The longitudinal opening on one side ofthe space 82 allows for faster insertion of both lead wires into this space, and cementing ofthe wires in this space, from the same side ofthe bobbin. The connecting portion more fully encloses and contains the cement and leads, making it feasible to use bifilar rather than individual lead wires in some applications.

Claims (11)

Claims

1. An inductive device having, in combination, a coil comprising a continuous winding of insulated wire formed of plural turns compacted around and spaced from an elongate axis, the coil extending between a pair of ends thereof mutually spaced on said axis, and a pair of mutually insulated lead wires extending internally ofthe winding between said ends, said lead wires extending externally ofthe winding from one of said ends and being respectively formed at the other of said ends as mutually separated start and finish posts, said posts extending in the axial direction away from the coil, each end ofthe winding being wrapped around one of said posts and electrically connected thereto.

2. An inductive device according to claim 1, in which at least one ofthe lead wires is bent to form a portion thereof extending in a direction away from said axis for separation of said lead wires.

3. An inductive device according to claim 2, in which both ofthe lead wires are bent to form portions thereof extending in mutually displaced directions away from said axis.

4. An inductive device according to claim 1, including a core of magnetic material extending internally ofthe winding.

5. An inductive device according to claim 4, in which the core is a bobbin comprising a pair of mutually connected members having portions thereof extending axially through the winding and forming spaces for passage of said lead wires.

6. An inductive device according to claim 5, in which each of said members is formed of sheet material, said axially extending portions thereof being connected in mutually spaced relationship.

7. An inductive device according to claim 6, in which each of said members has portions thereof extending in planes substantially normal to said axis for confining the winding in the axial direction.

8. An inductive device according to claim 4, in which the core is a bobbin having at least two portions thereof extending axially through the winding and mutually spaced to provide a passage for said lead wires.

9. An inductive device according to claim 8, in which the core is a unitary body formed of sheet material.

10. An inductive device according to claim 9, in which the core comprises a connecting portion extending integrally between said at least two portions and bent to form a closed side of said passage and a longitudinal opening on the other side thereof for insertion of said lead wires.

11. An inductive device according to claim 10, in which said lead wires are cemented within said passage.