DE2401492A1 - ELECTRIC COIL AND METHOD OF MANUFACTURING IT - Google Patents

Description

Andrejewski, Honke & Gesthuysen patent attorneys

2A01492 Graduate physicist

Dr. Walter Andrejewski graduate engineer Dr.-lng. Manfred Honke

,, M.Sc.

Attorney's file: 43 115 / Ti-th Hans Dieter Gesthuysen

4300 Essen, January 11, 1974 Theaterplatz 3

Patent application
Dainippon Printing Co., Ltd.
No. 12, 1-chome, kaga-cho,
Ichigaya, Shinjuku-ku,
Tokyo / Japan

Electric coil urid method of its manufacture.

In the manufacture of coils such as those in electrical machines and devices of various types are used, e.g. in electric motors, transformers, transmitting and receiving systems, Measuring devices etc., insulated wires are usually wound onto a corresponding bobbin or core or " Coils printed on insulating plates. While in the latter case it is generally relatively simple in terms of its quality and to produce coils that are consistent with their characteristics, production runs into difficulties when there are large numbers of turns

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Andrejewsici, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz

and there are coils with large dimensions. In the former case, the production of the coils takes part large number of turns no particular difficulties, but it is difficult here to produce coils of consistent quality and to produce consistent properties in large series.

In the manufacture of transformer coils, insulated wire of the required length and length is usually used Number of turns initially wound up as a primary winding, whereupon the secondary winding is applied in the same way is wrapped. Here it encounters difficulties in producing intermediate taps. The manufacture of transformer coils as a whole is therefore often quite difficult. Especially with large numbers of turns, it is inevitable that the Coil dimensions become very large and in series production there are qualitative differences also with regard to the features.

In the manufacture of electric motors, the insulated wire is usually placed on an iron core in a very special way wound up, i.e. inserted into the slots of an iron core. Particular care must be taken here, especially with small engines are used and special machines have been developed for this purpose. The are suitable for inexpensive mass production However, previously conventional methods are not and it is also difficult to produce such coils in a consistent quality and to produce with consistent properties, whereby the formation of intermediate taps is often extremely cumbersome and is time consuming.

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Andrejewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 3

240H92

The invention aims to remedy this and an electrical one Realize coil and a method for their production in such a way that the aforementioned disadvantages of the hitherto customary Coils and in particular their manufacturing processes cleared will. In other words, the invention aims to show a way how an electric coil works for any one Purpose with constant characteristics can be easily and conveniently produced even in large numbers, with Even with a large number of turns, the coil dimensions are small compared to the coils customary up to now.

An electrical coil according to the invention is essentially characterized in that it consists of one of the number of desired Coil turns accordingly on a bobbin or core wound flexible coil tape, which in turn made of at least one flexible, electrically insulating one There is a carrier tape with a number of parallel lines arranged thereon and the ends of these parallel lines Lines are connected to one another in such a way that they are connected in series.

In terms of the method, the invention proposes that BEZW on a carrier tape made of flexible insulating material. between- = see two carrier tapes a number of lines are arranged parallel to each other in the longitudinal direction, this coil tape is wound on a bobbin or core according to the desired number of coil turns, the two Ends of the coil tape are pulled out laterally and placed one on top of the other in such a way that the line ends are each around the

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Andrejewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 3

The distance between the lines are shifted from one another, whereupon the line ends lying on top of one another are connected to one another so that a continuous coil with two connections is created.

To produce a transformer coil, the invention provides that BEZW on a carrier tape. between two carrier tapes made of flexible insulating material at least two groups of lines arranged parallel to one another in the longitudinal direction be, the resulting coil tape according to the number of desired transformer turns on a suitable Core is wound up, the laterally pulled-out tape ends by the distance between two lines running next to one another are shifted and placed on top of each other and the ends of the lines lying on top of each other are connected to one another, so that at least two transformer windings with two connections each arise.

A coil for an electric motor is produced according to a further proposal of the invention in such a way that between two carrier tapes made of flexible insulating material a number of electrical lines parallel to each other in the longitudinal direction is arranged, the resulting coil tape is folded in such a way that the current directions in coil parts, which through a number of poles opposite to the coil band correspond to certain equal angles, coincide that the Coil tape wound onto a corresponding core and its two ends are connected to one another in such a way that the lines form an endless circuit.

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Andrejewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 3

240H92

In this way, spools can be used for a wide variety of purposes quickly and easily with just a few winding processes in constantly recurring training, i.e. with consistent quality, in small dimensions even with a large number of turns produce.

A more detailed explanation of the invention results from the following description of some preferred exemplary embodiments of electrical coils according to the invention; show it:

Figure 1 is a perspective view of a first embodiment of a coil according to the invention;

Figure 2 shows the same coil at the beginning of the WiekelVorganges;

Figure J is a plan view of that for making the coil reel tape used from Fig.l;

Figure 4 is a perspective view of a second Embodiment, a transformer coil;

FIG. 5 shows a representation of this transformer coil corresponding to FIG. 2;

Figure 6 is a plan view of the for making this Transformer coil used coil tape;

FIG. 7 shows the perspective illustration of a third exemplary embodiment;

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Andrejewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplafz 3

240H92

Figure 8 shows the coil from Pig. 7 at the beginning of the winding process;

FIG. 9 is a plan view of the reel tape used to manufacture the reel of FIG. 7;

FIG. 10 shows a plan view of a reel tape for producing a reel according to the invention for an electric motor;

FIGS. 11 and 12 show the individual phases in the manufacture of a motor coil; and

Figure I ^ the perspective view of a motor coil.

The electrical coil according to the invention shown in Figure 1 is made from a coil tape 3 , which consists of a number of parallel electrical lines 2 ^, 2 ^, ... 2 between two bands la and Ib, for example made of plastic.

In the manufacture of such a coil, a number of parallel lines 2, 2, 2, ... 2 are arranged between two strips _{1 a and 1 b made of plastic.} This reel tape 3 is wound up on a reel body or a suitable frame so often that the desired number of turns of the coil is produced, whereupon the excess end of this reel tape 3 is cut off. The ends of this reel tape 3 are then pulled out laterally, placed one on top of the other and displaced transversely to one another by the distance between two lines running next to one another. The ends of lines 2 ^, 2 ^, ... 2 v / then ground

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Andrejewskf, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 3

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exposed and electrically connected to one another in such a way that the electrical lines 2 ^, 2g, ... 2 are connected in series, for which purpose the left end 2 ,, of the line 2 is connected to the right end 2 _{2a of} the line 2 ₂ , the left end 2p, the line 2p is connected to the right end 2, the line 2-, etc. In this way, an air-core coil with coil terminals 2 and 2 can be obtained.

The reel tape 3 is preferably cut to the required length before being wound up, and its ends are then exposed, as shown in FIG. The ends of the lines 2 ^, 2g, ... 2 _n can be connected to one another by an electrically conductive adhesive or by soldering. Of course, the finished coil can then be embedded in an insulating compound or fixed with a suitable insulating binder so that it retains its shape.

The above-described coil can also be produced from a coil tape 3 which has a corresponding number of parallel lines 2 », 2 ₂ ,... 2 on a single plastic tape. In order to prevent the conductors from coming into undesired contact with one another in the bent area of the coil tape 3, the parts of the lines where this risk exists must naturally be insulated. The advantage here, however, is that the ends of the lines do not have to be exposed. Since, with such a design, the reel tape 3 only has a single plastic tape with the lines 2 ^ ₃ 2g, ... 2 _{n arranged on} it,

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Andrejewski, Honice & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplafz 3

This results in a smaller external dimension for such a coil with the same electrical values compared to the first-mentioned one Embodiment.

In the manner described above, by winding the reel tape J on a hollow core produce a hollow core coil, while to produce an iron core coil the coil tape on the corresponding iron core is wound up. In addition, it is easily possible to produce coils of various shapes, i.e. round or rectangular coils. Any flexible insulating tape can be used with the carrier tape, as long as its physical strength is sufficient, to ensure the desired spacing between the parallel lines.

The exemplary embodiment of a coil according to the invention shown in FIGS. 4, 5 and 6 is a transformer coil which is made from a coil strip IJ. This reel tape IJ consists of two carrier tapes 11a and 11b made of flexible insulating material, between which two groups of parallel lines 12, 12p, ... 12 and 12, _t , 12 ₂₁ , ... 12 are arranged. To produce the transformer coils from this coil tape IJ, the beginning of the coil tape is first bent to the side and the coil tape IJ is then wound onto a bobbin according to the required number of turns. Then the free end is again bent to the same side as the beginning and cut to the required length. The lines are then exposed at both ends of the coil that are led out laterally, and one of them

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Andrejewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 3

240U92

Tape end shifted relative to the other in such a way that the ends 12 _2a and 12 _2a - 'of the lines 12 ₂ and 12g ¹ above the ends 12. ,, and 12 _lb ' of the lines 12 ₁ and 12 ^ '. The other line ends then automatically lie exactly one above the other and can now be connected to one another so that the lines in each group are connected one behind the other. In this way, a coil is created which has two hollow core coils with connections 12, and 12, respectively. 12 '. and 12 '. Using la nb la mb

such a coil can be "a transformer produce, which has the advantage of very small dimensions over the previously common transformers with always has consistent electrical properties.

Even with such a transformer coil, the connection the cable ends are made by means of an electrically conductive adhesive or by soldering and the finished The coil can be embedded in insulating material or fixed with a suitable insulating binder. Also can the two groups of parallel lines are also arranged on a single flexible insulating carrier tape, as in the first embodiment, the same precautions must be taken to avoid undesirable Contacts between the individual lines are switched off. That thereby the outer dimensions of such a transformer coil let it be reduced again, of course.

The transformer coil described above consists of two coils, i.e. a primary winding and a secondary winding, however

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can of course also have more than two coils in the above-described Way to be made. By appropriate selection of the connection points of the lines, of course, any Taps are provided.

In Figures J, 8 and 9, a third embodiment of a coil according to the invention is shown, which is relatively wide compared to the inner diameter. In the illustrated embodiment, eight parallel lines 22 ^ - 22g are arranged in the longitudinal direction between two flexible insulating tapes 21a and 21b. The beginning of this reel tape 23 is then separated in the longitudinal direction between the fourth line 22h and the fifth line 22j-, so that two parts 23a and 23a ¹ arise, while the other end of the reel tape 23 between the fourth line 22w and the third line 22_ in the same way Way is separated so that two parts 23b and 23b ^f arise. The parts 23a and 23a ¹ at the beginning of the reel tape 23 'are then bent over in opposite directions so that the ends protrude on the sides of the reel to be produced. The coil tape 23 is then wound on a hollow core, an iron core or another desired core in the desired number of turns and then the ends 22 ^ _a - 22g _a and 22 _lb - 22g _{b of} the lines 22 _χ - 22g exposed. The parts 23b and 23b ^{r of} the outer end of the reel tape 23 are then also bent opposite to one another so that they protrude laterally from the reel, as FIG. 7 shows. These parts 23b and 23b ¹ are then placed on the parts 23a and 23a ¹ of the beginning of the tape in such a way that the beginnings ²² _2a - ²² £ j _{a of} ^the lines 22p - 22g each on the ends 22 ^ - 22_ of the

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Lines 22 ^^ - 22 "lie. After connecting the line ends lying on top of one another, there is then a coil with terminals 22 _{la and 22g b} for the lines 22 ^^ and 22g.

With such a coil, the same measures are of course also possible as in connection with the the above-described examples were mentioned, i.e. the embedding in or fixing with an insulating material, and the electrical Lines can of course also be arranged on a single carrier tape just as well.

In the case of the one shown in FIGS. 10 to 12. Embodiment is a coil for an electric motor. For this purpose, between two flexible insulating tapes Jl and J2. made of plastic or the like. For example four parallel lines 33i-33h. ^{arranged in the} longitudinal direction. This coil tape 3 ^ is then folded in such a way that the current in the coil parts a, - a., And b, - b, corresponding to the same electrical angle, which is determined by the number of poles in the motor confronted with the coil tape, for example at two poles angles of 0 °, 36o ° -720 °, 18o °, 54o ° -9OO °, flowing in the same direction. The coil tape y \ folded in this way is then wound, for example, with two turns on a corresponding core, whereupon the two ends of the coil tape are connected to one another in such a way that the lines 33 ^ - 33 ^ are placed one behind the other, so that a closed circuit is created. For this purpose, one end 33 _{la of} the line 3J _{1 is} connected to the other end 33 ^ of the line, one end 33 _{2a of} the line 33 ₂ with the

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Andre jewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 3

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the other end 33 _{lb of} the line 33. ^ one end 33-z _{a of} the line 33-, with the other end 33 _{2b of} the line 33 ₂ ^and one end 33ii _{a of} the line 33ψ with the other end 33 · ^ of the line 33 For this purpose, the ends of the lines 33i - 33ii must of course be exposed and, after the two ends of the reel tape 34 have been placed on top of one another, these two ends must be shifted towards one another in such a way that the line ends are on top of one another and can easily be connected or soldered to one another by means of an electrical adhesive so that all lines are placed one behind the other and an endless coil is created.

If one now assumes that the ends _b 33 ^ and 33 _2a ^{of the} obligations 33i and 33 ₂ positive with the clip and the ends _b 33 ^ and 33ii _a of the lines for 33 and 33h ^mi t the negative terminal of a power source , the current flows in the coil part a, - a., through all lines in the same direction as in the lines of the coil part b ₁ - b. ,, but the direction of flow in one group, ie in one coil part opposite to the direction of flow runs in the other part of the coil, so that the north and south poles are created and, as a result, a coil for a DC motor is completed.

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Claims (6)

Andrejewski, Honke & Gesthuysen, near the godparents, 4300 Essen 1, Theaterplatz 3 2A0H92 - 13 claims: ζ 1.J electrical coil, characterized in that it consists of a flexible coil tape (3; 13; 23; 3 ² O, which in turn consists of at least one flexible, electrically insulating carrier tape ( Ij 11; 21; 31) with a number of parallel lines (2; 12; 22; 33) arranged thereon and wherein the ends of these parallel lines are connected to one another in such a way that they are connected in series. 2. A method for producing a coil according to claim 1, characterized in that on a carrier tape (1; 11; 21; 31) made of flexible insulating material respectively. between two carrier tapes (la, Ib; 11a, 11b; 21a, 21b; 31, 32) a number of lines (2; 12; 22; 33) parallel to one another in the longitudinal direction be arranged, this coil tape (3 * 13; 23; 3 ^) accordingly the desired number of coil turns is wound onto a bobbin or core, the two ends of the Coil tape are pulled out laterally and placed one on top of the other in such a way that the line ends are each by the distance of the lines are shifted against each other, whereupon the line ends (2 ,,, 2p; 2p ,, 2,, ... 2) are connected to each other, so that a llcl Xl * " Xj going coil with two connections (2 _la , 2 _nb ) is created 409830/0807 Andre jewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 240U92 - 14 - 3 «A method for producing a coil according to claim 1 as a transformer coil, characterized in that on one Carrier tape (11) respectively. between two carrier tapes (11a, lib) made of flexible insulating material at least two groups of Lines (12 ^ -12, 12 ^ 1-12 ι) parallel to each other in the longitudinal direction be arranged, the resulting coil tape (IjJ) is wound on a suitable core according to the number of desired transformer turns, which is laterally pulled out tape ends shifted by the distance between two lines running next to each other placed one on top of the other and the ends of the lines lying on top of one another are connected to one another, so that at least two transformer windings with two connections each. 4 · Method for producing a coil, according to claim 1, characterized in that on a carrier tape (21) respectively. between two carrier tapes (21a, 21b) made of flexible insulating material η lines (22, ... 22) are arranged parallel to each other in the longitudinal direction, the resulting coil tape (23) at the beginning between a line (m) and the line (m + 1 ) is cut in the longitudinal direction into two parts (23a, 23a ¹ ) and at the end between the line (m) and the line (m-1) in the longitudinal direction into two parts (23b, 23b ¹ ), the two parts at the beginning of the reel tape are folded outwards in the opposite direction, the coil tape is then wound onto a core according to the desired number of turns and the two parts at the end are also folded sideways outwards, so that in each case a starting part lies on an end part, whereupon the line ends lying on top of one another are connected and one continuous coil with two connections (22, and 22 _nb ) is created. 409830/0807 Andre jewski, Honke & Gesthuysen, patent attorneys, 4300 Essen 1, Theaterplatz 3 - 15 - 5. A method for producing a coil according to claim 1 as a coil for an electric motor, characterized in that a number of electrical lines (3J ₁ -JJ ^) are arranged parallel to one another in the longitudinal direction between two carrier strips (31, 32) made of flexible insulating material, the resulting coil tape (34) is folded in such a way that the current directions coincide in coil parts which correspond to the same angle determined by a number of poles opposite the coil tape, so that the coil tape is wound onto a corresponding core and its two ends are connected to one another in this way that the lines form an endless circuit. 6. The method according to claim 5, characterized in that the coil tape (34) is folded obliquely in such a way that by changing the folding direction for the same pole angle corresponding coil parts result in the same current directions, and that the two tape ends after winding the coil tape on a corresponding one Core are placed on top of one another shifted by the distance between the parallel lines and the line ends are connected in series to form an endless line loop. Patent attorney. 409830/0807