CA1208322A - Coil form for electrical devices - Google Patents
Coil form for electrical devicesInfo
- Publication number
- CA1208322A CA1208322A CA000430489A CA430489A CA1208322A CA 1208322 A CA1208322 A CA 1208322A CA 000430489 A CA000430489 A CA 000430489A CA 430489 A CA430489 A CA 430489A CA 1208322 A CA1208322 A CA 1208322A
- Authority
- CA
- Canada
- Prior art keywords
- coil
- flexible hinge
- bending line
- windings
- parts
- 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
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/02—Coils wound on non-magnetic supports, e.g. formers
Abstract
ABSTRACT OF THE DISCLOSURE
Disclosed is a coil form manufactured by an injection molding process in a single split mold. The coil form in its unfolded condition is produced in the mold defines two mold halves interconnected by flexible hinge bands. After folding the halves by turning the same about 180° along the hinge bands pin and hole connections secure the coil form in its final posi-tion. In a preferred embodiment, there are provided four form halves connected along one bending line by the flexible hinge bands and further connected by a transverse hinge band so that upon folding the mold parts along one bending line, the coil windings are applied simultaneously and thereafter the tubular mold parts are bent along the transverse second bending line and the free ends of the coils are soldered to contact yokes which are secured from opposite sides to the windings by means of an adhesive tape or by a plastic coating.
Disclosed is a coil form manufactured by an injection molding process in a single split mold. The coil form in its unfolded condition is produced in the mold defines two mold halves interconnected by flexible hinge bands. After folding the halves by turning the same about 180° along the hinge bands pin and hole connections secure the coil form in its final posi-tion. In a preferred embodiment, there are provided four form halves connected along one bending line by the flexible hinge bands and further connected by a transverse hinge band so that upon folding the mold parts along one bending line, the coil windings are applied simultaneously and thereafter the tubular mold parts are bent along the transverse second bending line and the free ends of the coils are soldered to contact yokes which are secured from opposite sides to the windings by means of an adhesive tape or by a plastic coating.
Description
~8312~
1 The present invention relates in general to coil forms and in particular to coil forms of the type having a tubular body for supporting coil windings and being provided a-t each end thereof with a flange or collar for confining coil windings.
Coil forms of this kind find application in large quantities in many fields of technology. In particular, such coil forms are employed in electromagnetically actuated switching devices, such as for example circuit breakers. Hitherto, the manufacture of coil forms was relatively expensive, even if they are produced in large quantities. For example, to produce such a form from a synthetic material, a very complicated injection split mold is necessary. Such a split mold is composed of two disconnectable mold blocks which define the contour of the outer surface of the tubular body of the form as well as the opposite inner surfaces of the end flanges. Moreover, two additional mold parts must be provided for shaping the outer surfaces of the end flanges, and also a core or pin is used for delimiting the central hollow space of the tubular body. Such ccmplex component parts of the injection split mold must fit together with extreme accuracy, and also it is necessary in opening or closing the mold to move the mold parts along exactly predetermined paths. In spite of the most accurate manufacture and guidance of the component parts of the injection mold, the formation of seams or fins on completed forms frequently cannot be avoided, inasmuch as plastic material injected under pressure into the mold penetrates into the joints of the mold parts. The formation of such seams on the periphery of the hollow form bodies is particularly detrimental inasmuch as sharp seams or fins can damage the applied coil windings. Additional machining of the completed coil forms, for example by grinding off the seam, is cumbersome and, due to the projecting end flanges on ~LZ~33~Z
1 which the fins may also occur/ is very difficult to accomplish.
The two opposite, radially outwardly projecting end flanges cannot be dispensed with, as -they are necessary for laterally bounding and protecting the coil applied on the supporting tubular body.
It is therefore a general object of the present invention to avoid the aforementioned disadvantages.
In particular, it is an object of the invention to provide a coil body of the aforedescribed kind which is easy to manufacture.
Another object of this invention is to provide such an improved coil form which is free of surface defects resulting from processing in the injection mold.
In keeping with these objects and others which will become apparent hereafter, one feature of the invention resides in the provision of the tubular body with radially projecting end flanges, which is composed of two parts adjoining each other in a separation plane extending at right angles to the end flanges, and at least one flexible hinge band connects the two parts along a separation line.
In this manner, a substantial advantage is achieved in that for manufacturing the entire coil form by an injection molding process, only two mold parts are needed, and the movements for openiny and closing the mold are very simple and fast. In addition, there are no seams or fins on the surface of the tubular form body on which the coil windings are to be applied.
The novel features which are considered characteristic for the invention are set forth in particular in the appended claims.
The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from thefollowing description of specific embodiments when read in connection with the accompanying drawing.
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l FIG. l is a perspective view of a coil form of this invention shown in its unfolded position in which it is manufactured by an injection molding process;
FIG. 2 is a perspective view of the form of FIG. l in its folded condition;
FIG. 3 is a side view of the form of FIG. 2 in direction of arrow III;
FIG. 4 shows a perspective view of a modification of the coil form, shown in its unfolded position, in which two forms of FIG. 1 are combined in a single unit;
FIG. 5 is a plan view of the form of FIG. 4 shown in the direction V;
FIG. 6 is a side view of the form of FIG. 5, shown in direction ox arrow VI;
FIG. 7 is a front view of the form of FIG. 5, shown in the direction of VII;
FIG. 8 is a view similar to FIG. 7, showing the form in its folded position;
FIG. 9 is a side view of the form of FIG. 8 in the direction of arrow IV;
FIG. lO is a perspective view of the coil form of FIG. 9;
FIG lL is a view similar to FIG. 10, showing the form with applied coil windings;
FIG. 12 is a perspective view of a completed coil; and FIG. 13 is a perspective view of the coil of FIG. 12 coated with an outer layer of plastic material.
FIGS. 1-3 show an embodiment of a single coil form for supporting a single winding. The form consists of two halves l and 2, manufactured simu]taneously by an injection molding process and, as will be explained below, the resulting completed coil form is divided ~8.~Z2 1 lengthwise along a plane extending pexpendicularly to the end flanges of the coil form. The separation plane is indicated in FIG. 3 by reference numeral 13. According to this invention, the two parts 1 and 2 of the form are interconnected by two flexible hinge bands 16 and 17 which are also produced simultaneously with the injection molding of the form halvesO In this embodiment, the form in its folded condition has the shape of a hollow or tubular body of a substantially rectangular cross section. It will be seen from FIGS. 1 and 2 that the rectangular full size surfaces 3 and 4 in folded condition of the form are placed opposite each other, and the half surfaces 5, 6 and 7, adjoin one another along the separation plane 13 to form lateral walls of the central channel of the coil form. It will be seen from FIG. 2 that the outer surfaces of the rectangular sides have rounded edges.
In this preferred embodiment, the separation plane 13 bisects the coil form into two symmetrical halves 1 and 2. accordingly, the end flanges 9, 10 and 11, 12 are also composed of symmetrical halves projecting radially from the ends of the tubular body 1 and 2. The outer faces of the flanges are provided with reinforcing ribs 14 and 15. By virtue of the two flexible hinge bands 16 and 17, which in this embodiment 20 connect the opposite corners of divided flanges 11, 12 and 9 and 10, the both halves of the coil form can be readily rotated by 180 from their unfolded position shown in FIG. 1 into their folded, final position shown in FIG. 2.
In its unfolded position, in which the coil form is produced in the injection mold, the form has no undercuts, and consequently the manufacture of the form proceeds in a very simple manner in only two mold parts by an injection molding process. One of the mold parts defines the upper contour of the form, and the other mold part corresponds to the lower contour. Both form halves 1 and 2 and the interconnecting flexible hinge bands 16 and 17 form together a single piece of tough ~Z~33~
1 and hard plastic material. The flexible hinge bands 16 and 17 are so thin that the plastic material in this range still maintains the desired flexibility or bendability, while maintaining a strong connection between the two form halves 1 and 2. Preferably, the two flexible hinge bands 16 and 17 are formed with advantage between the outermost separation lines, which in this example are at the plane of separation between the narrow sides of the end flanges 9, 10 and 11, 12. After the coil form is removed in its unfolded condition from the injection mold, the two form halves 1 and 2 are folded together by rotation by 180 as indicated by dashed arrows 22 and 23. In order to obtain a fixed contact in the folded position, the facing surfaces of the form halves are provided in the separation plane 13 with project-ing pins 20 on one half and with corresponding retaining holes 21 on the opposite half for snugly engaging the pins 20. Preferably, there are provided four holding pins 20 with corresponding holes 21 in the end regions of the dividing surfaces 18 and 19, that is in the range of the end flanges 9-12, so as to ensure a reliable connection of the two mold halves. In its folded or assembled condition, the coil form is provided with coil windings in conventional fashion.
A preferred embodiment of this invention which is particularly important in practice is illustrated in FIGS. 4-12. In this preferred embodiment, the two form halves 24, 25 and 26, 27 are arranged end-to-end and axe interconnected by a flexible hinge band 36 (FIG. 5) to a single unit. The individual single winding coil forms or form halves 24, 25 and 26, 27 correspond in all details to the form halves 1 and 2 of FIGS. 1-3. In other words, the form halves 24 and 25 are again interconnected by flexible hinge bands 28 and 29 and the adjoining form halves 26 and 27 are provided with flexible hinge bands 30 and 31.
Similarly, the xetaining pins 32 and 34 and corresponding snugly fitting holds 33 and 35 are equal to those of FIG. 1. The manufacture of the .3~2 1 unfolded double form is also made in the manner described in connection with FIG. 1. Since the double coil form is held together by the flexible hinge band 36, it can be remcved fro~l the injection molding device as a single unit.
Thereafter, the form halves 24, 25 and 26, 27 are bent along the flexible hinge bands 28 31 about 18Q and snapped together into the completed coil form illustrated in FIG. 8. The provision of the flexible hinge band 36 between the outer rims of facing end flanges of series-arranged coil worms does no-t obstruct the folding of the two coil forms along the aligned hinge bands 28-31. In the folded condition shwon in FIGS. 8-10 the end flanges of the axially aligned, series-connected tubular forms are arranged parallel to each other. The outer surfaces of respective flanges, similarly as in the preceding example, are provided with reinforcing ribs. These ribs in the range between the consecutive coil forms, serve simultaneously as spacers. In the folded condition of this double coil form, the coil windings 40 and 41 (FIG. 11) can be wound simultaneously on both supporting tubular bodies.
This possibility, in comparison with the prior art technology, has the essential advantage that the winding time is cut by half, inasmuch as it is possible without any additional measures to clamp both coil forms on a single winding machine. After the first mentioned folding of the form halves in the direction of arrow 39 (FIG. 8) about the flexible hinge bands 28-31, and after the application of windings 40 and 41 on the tubular body, a further folding of the form is made, namely about the flexible hinge band 36 in the direction of arrow 42 (FIG. 11). It will be seen from FIGS. 5 and 9 that the flexible hinge band 36 extends at right angles to the flexible hinge bands 28-31, and consequently the two consecutively arranged coil forms with their windings 40 and 41 can be folded into a new position illustrated in FIG. 12, in which the windings are arranged parallel to one another. In this final position, 332~
1 the corresponding narrow sides of the end faces abut against each other, and the center axis of respective tubular bodies of the form extend in parallel. In order to secure the coil form in this final position, there is provided a projecting pin 37 and a corresponding retaining hole 38 on the narrow sides of the end flanges which are remote from the flexible hinge band 36~
The end portions of the wires 43 of windings 40 and 41 can be now simply twisted together and soldered, whereas the free ~Jires are comlected each Jo a conductive yoke 4. The yokes are clamped to opposite outer edges of adjoining end flanges, as depicted in FIG. 12.
Preferably, each yoke is shaped so as to define an outwardly projecting knee with a conductive contact surface 45. The knee projects outwardly to such an extent that, after the insertion of the completed coil body in an electromagnetic device, for example a circuit breaker or magnetic switch, a conductive contact with non-illustrated terminals, such as conductive rails on the device, is established.
In order to protect the two windings ~0 and 41 and to hold the contact yoke 44 in position, both windings are coated by an in-sulating adhesive band. The protective insulating band is provided with small cut-outs to uncover the conductive areas 45 on the yokes 44.
Instead of adhesive bands, it is also possible to coat the entire outer surface of the coil with a closed layer of a plastic material through which the contact surfaces 45 project (FIG. 13). In the completed coil according to FIGS. 12 or 13 the hollow channels 47 and 48 in the centers of respective coil forms remain open, so that the coils can be inserted in conventional manner on the arms of a U-shaped electromagnetic core.
The embodiment according to FIGS. 4-13 has the following substantial advantages.
As mentioned before, the manufacturing process is consider-ably simplified, whereby the halves of the split injection mold can ~2l)8~,~2 l be constructed in such a manner that no detrimental seams and separation edges will result in the range of the form where the coil windings are to be applied. The separation gaps in the coil form if desired can serve also as a very simple intake pocket for the terminal wires of respective windings. The two windings can be simultaneously produced during a single winding process. The con-ventional tubing for protection of the soldered sections on the ends of the wires can be dispensed with, and it is also no longer necessary to solder additional flexible conductors to the ends of the winding.
lQ The halves of the coil form are rigidly connected one to the other by means of the aforedescribed flexible hinge bands as well as by the pin and hole connections, and consequently thin wires interconnecting the two separate windings on the composite coll form are not subject to any load. Inasmuch as the two consecutive coil forms, together with their windings, are united in a single unit, the storage of the coils is simplified and also is increased safety margin against damage during transportation and during insertion into the electromagnetic cores The construction of electrical contacts in the electromagnetic devices is also simplified.
It will be pointed out that the aforedescribed flexible hinge bands 28-31 and 36, during the injection of a plastic mass of a synthetic plastic material, permit the through-flow of the material in the injection mold. Accordingly, it is sufficient to provide for a single injection channel at a suitable point of the split mold for injection the material in both form halves. In this mannert the manufacture and design of injection molds is in practice substantially facilitated.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
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1 While the invention has been illustrated and described as embodied in speclfic examples of a coil mold for use with electromagnetie devices, it i5 not intended to be limited to the details shown, since various modi*icat:i.ons and structural ehanges may be made without departing in any way from the spirit of the present invention.
1 The present invention relates in general to coil forms and in particular to coil forms of the type having a tubular body for supporting coil windings and being provided a-t each end thereof with a flange or collar for confining coil windings.
Coil forms of this kind find application in large quantities in many fields of technology. In particular, such coil forms are employed in electromagnetically actuated switching devices, such as for example circuit breakers. Hitherto, the manufacture of coil forms was relatively expensive, even if they are produced in large quantities. For example, to produce such a form from a synthetic material, a very complicated injection split mold is necessary. Such a split mold is composed of two disconnectable mold blocks which define the contour of the outer surface of the tubular body of the form as well as the opposite inner surfaces of the end flanges. Moreover, two additional mold parts must be provided for shaping the outer surfaces of the end flanges, and also a core or pin is used for delimiting the central hollow space of the tubular body. Such ccmplex component parts of the injection split mold must fit together with extreme accuracy, and also it is necessary in opening or closing the mold to move the mold parts along exactly predetermined paths. In spite of the most accurate manufacture and guidance of the component parts of the injection mold, the formation of seams or fins on completed forms frequently cannot be avoided, inasmuch as plastic material injected under pressure into the mold penetrates into the joints of the mold parts. The formation of such seams on the periphery of the hollow form bodies is particularly detrimental inasmuch as sharp seams or fins can damage the applied coil windings. Additional machining of the completed coil forms, for example by grinding off the seam, is cumbersome and, due to the projecting end flanges on ~LZ~33~Z
1 which the fins may also occur/ is very difficult to accomplish.
The two opposite, radially outwardly projecting end flanges cannot be dispensed with, as -they are necessary for laterally bounding and protecting the coil applied on the supporting tubular body.
It is therefore a general object of the present invention to avoid the aforementioned disadvantages.
In particular, it is an object of the invention to provide a coil body of the aforedescribed kind which is easy to manufacture.
Another object of this invention is to provide such an improved coil form which is free of surface defects resulting from processing in the injection mold.
In keeping with these objects and others which will become apparent hereafter, one feature of the invention resides in the provision of the tubular body with radially projecting end flanges, which is composed of two parts adjoining each other in a separation plane extending at right angles to the end flanges, and at least one flexible hinge band connects the two parts along a separation line.
In this manner, a substantial advantage is achieved in that for manufacturing the entire coil form by an injection molding process, only two mold parts are needed, and the movements for openiny and closing the mold are very simple and fast. In addition, there are no seams or fins on the surface of the tubular form body on which the coil windings are to be applied.
The novel features which are considered characteristic for the invention are set forth in particular in the appended claims.
The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from thefollowing description of specific embodiments when read in connection with the accompanying drawing.
3~;~
l FIG. l is a perspective view of a coil form of this invention shown in its unfolded position in which it is manufactured by an injection molding process;
FIG. 2 is a perspective view of the form of FIG. l in its folded condition;
FIG. 3 is a side view of the form of FIG. 2 in direction of arrow III;
FIG. 4 shows a perspective view of a modification of the coil form, shown in its unfolded position, in which two forms of FIG. 1 are combined in a single unit;
FIG. 5 is a plan view of the form of FIG. 4 shown in the direction V;
FIG. 6 is a side view of the form of FIG. 5, shown in direction ox arrow VI;
FIG. 7 is a front view of the form of FIG. 5, shown in the direction of VII;
FIG. 8 is a view similar to FIG. 7, showing the form in its folded position;
FIG. 9 is a side view of the form of FIG. 8 in the direction of arrow IV;
FIG. lO is a perspective view of the coil form of FIG. 9;
FIG lL is a view similar to FIG. 10, showing the form with applied coil windings;
FIG. 12 is a perspective view of a completed coil; and FIG. 13 is a perspective view of the coil of FIG. 12 coated with an outer layer of plastic material.
FIGS. 1-3 show an embodiment of a single coil form for supporting a single winding. The form consists of two halves l and 2, manufactured simu]taneously by an injection molding process and, as will be explained below, the resulting completed coil form is divided ~8.~Z2 1 lengthwise along a plane extending pexpendicularly to the end flanges of the coil form. The separation plane is indicated in FIG. 3 by reference numeral 13. According to this invention, the two parts 1 and 2 of the form are interconnected by two flexible hinge bands 16 and 17 which are also produced simultaneously with the injection molding of the form halvesO In this embodiment, the form in its folded condition has the shape of a hollow or tubular body of a substantially rectangular cross section. It will be seen from FIGS. 1 and 2 that the rectangular full size surfaces 3 and 4 in folded condition of the form are placed opposite each other, and the half surfaces 5, 6 and 7, adjoin one another along the separation plane 13 to form lateral walls of the central channel of the coil form. It will be seen from FIG. 2 that the outer surfaces of the rectangular sides have rounded edges.
In this preferred embodiment, the separation plane 13 bisects the coil form into two symmetrical halves 1 and 2. accordingly, the end flanges 9, 10 and 11, 12 are also composed of symmetrical halves projecting radially from the ends of the tubular body 1 and 2. The outer faces of the flanges are provided with reinforcing ribs 14 and 15. By virtue of the two flexible hinge bands 16 and 17, which in this embodiment 20 connect the opposite corners of divided flanges 11, 12 and 9 and 10, the both halves of the coil form can be readily rotated by 180 from their unfolded position shown in FIG. 1 into their folded, final position shown in FIG. 2.
In its unfolded position, in which the coil form is produced in the injection mold, the form has no undercuts, and consequently the manufacture of the form proceeds in a very simple manner in only two mold parts by an injection molding process. One of the mold parts defines the upper contour of the form, and the other mold part corresponds to the lower contour. Both form halves 1 and 2 and the interconnecting flexible hinge bands 16 and 17 form together a single piece of tough ~Z~33~
1 and hard plastic material. The flexible hinge bands 16 and 17 are so thin that the plastic material in this range still maintains the desired flexibility or bendability, while maintaining a strong connection between the two form halves 1 and 2. Preferably, the two flexible hinge bands 16 and 17 are formed with advantage between the outermost separation lines, which in this example are at the plane of separation between the narrow sides of the end flanges 9, 10 and 11, 12. After the coil form is removed in its unfolded condition from the injection mold, the two form halves 1 and 2 are folded together by rotation by 180 as indicated by dashed arrows 22 and 23. In order to obtain a fixed contact in the folded position, the facing surfaces of the form halves are provided in the separation plane 13 with project-ing pins 20 on one half and with corresponding retaining holes 21 on the opposite half for snugly engaging the pins 20. Preferably, there are provided four holding pins 20 with corresponding holes 21 in the end regions of the dividing surfaces 18 and 19, that is in the range of the end flanges 9-12, so as to ensure a reliable connection of the two mold halves. In its folded or assembled condition, the coil form is provided with coil windings in conventional fashion.
A preferred embodiment of this invention which is particularly important in practice is illustrated in FIGS. 4-12. In this preferred embodiment, the two form halves 24, 25 and 26, 27 are arranged end-to-end and axe interconnected by a flexible hinge band 36 (FIG. 5) to a single unit. The individual single winding coil forms or form halves 24, 25 and 26, 27 correspond in all details to the form halves 1 and 2 of FIGS. 1-3. In other words, the form halves 24 and 25 are again interconnected by flexible hinge bands 28 and 29 and the adjoining form halves 26 and 27 are provided with flexible hinge bands 30 and 31.
Similarly, the xetaining pins 32 and 34 and corresponding snugly fitting holds 33 and 35 are equal to those of FIG. 1. The manufacture of the .3~2 1 unfolded double form is also made in the manner described in connection with FIG. 1. Since the double coil form is held together by the flexible hinge band 36, it can be remcved fro~l the injection molding device as a single unit.
Thereafter, the form halves 24, 25 and 26, 27 are bent along the flexible hinge bands 28 31 about 18Q and snapped together into the completed coil form illustrated in FIG. 8. The provision of the flexible hinge band 36 between the outer rims of facing end flanges of series-arranged coil worms does no-t obstruct the folding of the two coil forms along the aligned hinge bands 28-31. In the folded condition shwon in FIGS. 8-10 the end flanges of the axially aligned, series-connected tubular forms are arranged parallel to each other. The outer surfaces of respective flanges, similarly as in the preceding example, are provided with reinforcing ribs. These ribs in the range between the consecutive coil forms, serve simultaneously as spacers. In the folded condition of this double coil form, the coil windings 40 and 41 (FIG. 11) can be wound simultaneously on both supporting tubular bodies.
This possibility, in comparison with the prior art technology, has the essential advantage that the winding time is cut by half, inasmuch as it is possible without any additional measures to clamp both coil forms on a single winding machine. After the first mentioned folding of the form halves in the direction of arrow 39 (FIG. 8) about the flexible hinge bands 28-31, and after the application of windings 40 and 41 on the tubular body, a further folding of the form is made, namely about the flexible hinge band 36 in the direction of arrow 42 (FIG. 11). It will be seen from FIGS. 5 and 9 that the flexible hinge band 36 extends at right angles to the flexible hinge bands 28-31, and consequently the two consecutively arranged coil forms with their windings 40 and 41 can be folded into a new position illustrated in FIG. 12, in which the windings are arranged parallel to one another. In this final position, 332~
1 the corresponding narrow sides of the end faces abut against each other, and the center axis of respective tubular bodies of the form extend in parallel. In order to secure the coil form in this final position, there is provided a projecting pin 37 and a corresponding retaining hole 38 on the narrow sides of the end flanges which are remote from the flexible hinge band 36~
The end portions of the wires 43 of windings 40 and 41 can be now simply twisted together and soldered, whereas the free ~Jires are comlected each Jo a conductive yoke 4. The yokes are clamped to opposite outer edges of adjoining end flanges, as depicted in FIG. 12.
Preferably, each yoke is shaped so as to define an outwardly projecting knee with a conductive contact surface 45. The knee projects outwardly to such an extent that, after the insertion of the completed coil body in an electromagnetic device, for example a circuit breaker or magnetic switch, a conductive contact with non-illustrated terminals, such as conductive rails on the device, is established.
In order to protect the two windings ~0 and 41 and to hold the contact yoke 44 in position, both windings are coated by an in-sulating adhesive band. The protective insulating band is provided with small cut-outs to uncover the conductive areas 45 on the yokes 44.
Instead of adhesive bands, it is also possible to coat the entire outer surface of the coil with a closed layer of a plastic material through which the contact surfaces 45 project (FIG. 13). In the completed coil according to FIGS. 12 or 13 the hollow channels 47 and 48 in the centers of respective coil forms remain open, so that the coils can be inserted in conventional manner on the arms of a U-shaped electromagnetic core.
The embodiment according to FIGS. 4-13 has the following substantial advantages.
As mentioned before, the manufacturing process is consider-ably simplified, whereby the halves of the split injection mold can ~2l)8~,~2 l be constructed in such a manner that no detrimental seams and separation edges will result in the range of the form where the coil windings are to be applied. The separation gaps in the coil form if desired can serve also as a very simple intake pocket for the terminal wires of respective windings. The two windings can be simultaneously produced during a single winding process. The con-ventional tubing for protection of the soldered sections on the ends of the wires can be dispensed with, and it is also no longer necessary to solder additional flexible conductors to the ends of the winding.
lQ The halves of the coil form are rigidly connected one to the other by means of the aforedescribed flexible hinge bands as well as by the pin and hole connections, and consequently thin wires interconnecting the two separate windings on the composite coll form are not subject to any load. Inasmuch as the two consecutive coil forms, together with their windings, are united in a single unit, the storage of the coils is simplified and also is increased safety margin against damage during transportation and during insertion into the electromagnetic cores The construction of electrical contacts in the electromagnetic devices is also simplified.
It will be pointed out that the aforedescribed flexible hinge bands 28-31 and 36, during the injection of a plastic mass of a synthetic plastic material, permit the through-flow of the material in the injection mold. Accordingly, it is sufficient to provide for a single injection channel at a suitable point of the split mold for injection the material in both form halves. In this mannert the manufacture and design of injection molds is in practice substantially facilitated.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
_g _ ~Z~:~8~;~Z
1 While the invention has been illustrated and described as embodied in speclfic examples of a coil mold for use with electromagnetie devices, it i5 not intended to be limited to the details shown, since various modi*icat:i.ons and structural ehanges may be made without departing in any way from the spirit of the present invention.
Claims (15)
1. A coil form for electrical devices, particularly for electromagnetic switching devices, comprising a tubular form body of synthetic material having a flange at each end thereof, the tubular form body being composed of two parts which in an assembled condition of this form adjoin each other along a separation plane extending at right angles to the end flanges;
and at least one flexible hinge band of the same synthetic material integrally connecting outer edges of adjacent flange portions of the two parts in the separation plane when viewed in the assembled condition of the form; the flexible hinge band bridging the separation plane while, in a disassembled condition of the form, holding the two parts apart by a predetermined length.
and at least one flexible hinge band of the same synthetic material integrally connecting outer edges of adjacent flange portions of the two parts in the separation plane when viewed in the assembled condition of the form; the flexible hinge band bridging the separation plane while, in a disassembled condition of the form, holding the two parts apart by a predetermined length.
2. A coil form according to claim 1, wherein the tubular form body has a substantially rectangular cross section, said separation plane symmetrically dividing the form body into two halves, and the opposite edge portions of the two halves in the range of said end flanges being interconnected by two flexible hinge bands.
3. A coil form according to claim 2, wherein said flexible hinge bands interconnect the outer corners of opposite end flange halves.
4. A coil form according to claim 1, wherein the contact surfaces of the two form parts remote from the flexible hinge bands are interconnected by fitting pin and hole connections.
5. A coil form as defined in claim 4, wherein each end portion of contact surfaces of respective parts is provided with four pin and hole connections.
6. A coil form as defined in claim 1, wherein the outer surfaces of said end flanges are provided with reinforcing ribs.
7. A coil form as defined in claim 1, comprising an additional tubular form body adjoining in axial direction the first-mentioned tubular form body and being composed of similar two parts interconnected in the separation plane by at least one flexible hinge mount to fold simultaneously the two form bodies along a first bending line, and further comprising a transverse flexible hinge band connecting the opposite edges of adjoining end flanges of the first and additional form bodies to bend these bodies along a second bending line extending at right angles to the first bending line.
8. A coil form as defined in claim 7, wherein upon folding the coil form about the second bending line the narrow faces of the opposite end flanges abut against each other and the center axis of respective tubular form bodies extend at a spaced relationship parallel to one another.
9. A coil form as defined in claim 8, comprising coil windings on each tubular form body and contact yokes provided on opposite sides of respective coil windings and each having a projecting contact surface.
10. A coil form as defined in claim 9, wherein the outer surfaces of the coil windings are coated by an insulating adhesive tape.
11. A coil form as defined in claim 9, wherein the narrow sides of adjoining end flanges remote from the transverse flexible hinge band are provided with at least one pin and hole connection to hold the coil in its folded position.
12. A coil form as defined in claim 9, wherein two ends of respective coil windings are twisted together and/or soldered and the remaining ends of the coils are connected to the assigned conductive yokes.
13. A coil form as defined in claim 9, wherein the outer surfaces of the coil winding are covered with a protective coating of a plastic material.
14. A method of producing an electric coil having a coil form according to claim 9, comprising the steps of folding the form parts along the first bending line, then simultaneously applying a coil winding on each of the tubular form bodies, then folding the coil form along the second bending line, then applying contact yokes on opposite outer sides of the coil windings, then interconnecting two ends of the windings and connecting the other free ends to conductive yokes and protecting the outer surface of the windings by a protective coating.
15. A method of producing an electrical coil of the type having a tubular form body of a synthetic material, provided with a flange at each end thereof, the tubular form body being composed of two parts which in an assembled condition of the form adjoin each other along a separation plane extending at right angles to the end flanges, at least one flexible hinge band of the same synthetic material integrally connecting outer edges of adjacent flange portions of the two parts in the separation plane, the flexible hinge band bridging the separation plane while, in a disassembled condition of the form, holding the two parts apart by a predetermined length, an additional tubular form body adjoin-ing in axial direction the first-mentioned tubular form body and being composed of similar two parts interconnected in the separation plane by at least one flexible hinge mount to fold simultaneously the two form bodies along a first bending line, a transverse flexible hinge band connecting the opposite edges of adjoining end flanges of the first and additional form bodies to bend these bodies along a second bending line extending at right angles to the first bending line so that upon folding the coil form about the second bending line the narrow faces of the opposite end flanges abut against each other and the center axis of respective tubular form bodies extend at a spaced relationship parallel to one another, coil windings on each tubular form body and contact yokes provided on opposite sides of respective coil windings and each having a projecting contact surface, the method comprising the steps of folding the form parts along the first bending line, then simultaneously applying a coil winding on each of the tubular form bodies, then folding the coil form along the second bending line, then applying contact yokes on opposite outer sides of the coil windings, then interconnecting two ends of the windings and connecting the other free ends to conductive yokes and protecting the outer surface of the windings by a protective coating.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP82105391A EP0098887B1 (en) | 1982-06-19 | 1982-06-19 | Coil bobbin for electric devices |
| EP82105391.5 | 1982-06-19 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1208322A true CA1208322A (en) | 1986-07-22 |
Family
ID=8189094
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000430489A Expired CA1208322A (en) | 1982-06-19 | 1983-06-15 | Coil form for electrical devices |
Country Status (10)
| Country | Link |
|---|---|
| EP (1) | EP0098887B1 (en) |
| AT (1) | ATE22189T1 (en) |
| AU (1) | AU562401B2 (en) |
| BR (1) | BR8303235A (en) |
| CA (1) | CA1208322A (en) |
| DE (1) | DE3273162D1 (en) |
| DK (1) | DK388682A (en) |
| ES (1) | ES274744Y (en) |
| MX (1) | MX153675A (en) |
| NO (1) | NO823042L (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3407765C1 (en) * | 1984-03-02 | 1990-01-25 | Deutsche Basaltsteinwolle GmbH, 3406 Bovenden | Process and device for the production of, in particular, shell-like or tubular moldings, in particular. Hollow bodies |
| DE102004006712B4 (en) * | 2004-02-11 | 2006-08-31 | Tyco Electronics Amp Gmbh | Spool for an electromechanical actuator |
| JP6885100B2 (en) | 2017-02-23 | 2021-06-09 | スミダコーポレーション株式会社 | Filter parts assembly kit, filter parts, and manufacturing method of filter parts |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE478876C (en) * | 1929-07-09 | Aeg | Electricity meter | |
| GB621210A (en) * | 1946-04-10 | 1949-04-06 | Standard Telephones Cables Ltd | Improvements in or relating to spools and coils for electrical devices |
| DE1614632A1 (en) * | 1966-01-12 | 1970-12-03 | It Tecnomeccanica La Precisa D | Electromagnetic valve, e.g. for a gas safety device and method for its manufacture |
| DE2053941A1 (en) * | 1970-10-29 | 1972-05-04 | Siemens Ag | Spool form consisting of several parts |
| DE2138987B2 (en) * | 1971-08-04 | 1974-08-29 | Swf-Spezialfabrik Fuer Autozubehoer Gustav Rau Gmbh, 7120 Bietigheim | Winding body for two excitation windings |
| US3846725A (en) * | 1973-04-30 | 1974-11-05 | Gen Instrument Corp | Coil retainer |
| DE2360411C3 (en) * | 1973-12-04 | 1981-10-15 | Siemens AG, 1000 Berlin und 8000 München | Coil arrangement with a bobbin for double coils |
| DE2430034A1 (en) * | 1974-06-22 | 1976-01-08 | Hartmann & Braun Ag | Electromagnet with U-shaped core yoke - has coil formers on yoke shanks with series-connected coils and rod-shaped armature |
| FR2290748A1 (en) * | 1974-11-07 | 1976-06-04 | Centre Techn Ind Mecanique | Open coiled device for non-destructive testing |
-
1982
- 1982-06-19 EP EP82105391A patent/EP0098887B1/en not_active Expired
- 1982-06-19 AT AT82105391T patent/ATE22189T1/en not_active IP Right Cessation
- 1982-06-19 DE DE8282105391T patent/DE3273162D1/en not_active Expired
- 1982-08-26 ES ES1982274744U patent/ES274744Y/en not_active Expired
- 1982-08-31 DK DK388682A patent/DK388682A/en not_active Application Discontinuation
- 1982-09-08 NO NO823042A patent/NO823042L/en unknown
-
1983
- 1983-06-08 AU AU15613/83A patent/AU562401B2/en not_active Ceased
- 1983-06-15 CA CA000430489A patent/CA1208322A/en not_active Expired
- 1983-06-17 BR BR8303235A patent/BR8303235A/en unknown
- 1983-06-17 MX MX197701A patent/MX153675A/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| ES274744Y (en) | 1984-12-16 |
| EP0098887B1 (en) | 1986-09-10 |
| AU562401B2 (en) | 1987-06-11 |
| EP0098887A1 (en) | 1984-01-25 |
| ATE22189T1 (en) | 1986-09-15 |
| NO823042L (en) | 1983-12-20 |
| AU1561383A (en) | 1983-12-22 |
| DE3273162D1 (en) | 1986-10-16 |
| ES274744U (en) | 1984-05-16 |
| BR8303235A (en) | 1984-01-31 |
| MX153675A (en) | 1986-12-16 |
| DK388682A (en) | 1983-12-20 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |