EP0188095A1 - Verfahren zur Herstellung einer ringförmigen Vorschaltdrossel und Vorrichtung zur Durchführung dieses Verfahrens - Google Patents

Verfahren zur Herstellung einer ringförmigen Vorschaltdrossel und Vorrichtung zur Durchführung dieses Verfahrens Download PDF

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Publication number
EP0188095A1
EP0188095A1 EP85309051A EP85309051A EP0188095A1 EP 0188095 A1 EP0188095 A1 EP 0188095A1 EP 85309051 A EP85309051 A EP 85309051A EP 85309051 A EP85309051 A EP 85309051A EP 0188095 A1 EP0188095 A1 EP 0188095A1
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EP
European Patent Office
Prior art keywords
core
winding
layer
winding device
movement system
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.)
Withdrawn
Application number
EP85309051A
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English (en)
French (fr)
Inventor
Joseph A. Venezia
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.)
EAST ROCK TECHNOLOGY Inc
Original Assignee
EAST ROCK TECHNOLOGY 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 EAST ROCK TECHNOLOGY Inc filed Critical EAST ROCK TECHNOLOGY Inc
Publication of EP0188095A1 publication Critical patent/EP0188095A1/de
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus 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
    • H01F41/02—Apparatus 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
    • H01F41/04—Apparatus 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
    • H01F41/06—Coil winding
    • H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus 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
    • H01F41/02—Apparatus 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

Definitions

  • the present invention pertains generally to the field of lighting fixtures, and pertains more particularly to a process for manufacturing a generally toroidal ballast choke and to a winding machine suitable for use in manufacturing a generally toroidal ballast choke.
  • lighting fixtures intended for use with fluorescent and other bulbs of types with which a ballast, choke is used are frequently larger than those for incandescent bulbs of comparable bulk. It is often desirable to reduce the size of such fluorescent and similar fixtures as much as possible, whether to save space, or for reasons of economy or esthetics.
  • U.S. Patent 3,551,736 shows a fluorescent lamp in wnich a fluorescent bulb rests , on a ballast unit ana has electrical connector pins which extend through passages provided for them in the ballast unit.
  • the ballast unit also receives electrical connector pins from a terminal contact base which is externally threaded to be screwed into a conventional incanuescent lamp screw socket.
  • the ballast unit contains a toroidal ballast choke, with the connector pin passages extending through the hole of the torus.
  • the starter and the capacitor are located in the screw base unit.
  • a one-piece lighting fixture, wnicn may be a socket adapter, in which such a choke can suitaoly be used comprises a one-piece housing naving a recess formed therein for receiving the base of a light bulb, electrical circuitry including the ballast choke disposed in the housing, and electrical contact elements for connecting the electrical circuitry with an external power source.
  • the fixture is a socket adapter, it also has an external securing device for securing it to a socket.
  • tne electrical circuitry at least partially surrounds the recess, and most preierably the ballast choke is toroidal and surrounds the recess.
  • such a ballast choke is manufactured by providing a core made of a magnetic material, forming on the core a layer of an electrically insulative material, dividing the core into two pieces each of which bears a portion of the insulative coating, and wrapping a winding of an electrical conductor on each of the two pieces, with tne coating insulating the winding from the core.
  • the insulative layer is formed on the core by means of injection molding, or by placing the core in a mold made of a flexible material and introducing the insulative material into the mold, releasing the core by flexing the mold after the insulative material has set.
  • the dividing step is preferably, but not absolutely necessarily, performed after the provision of the insulative layer.
  • the two resulting chokes can be used separately, or can be electrically connected in series with or without a mechanical connection to form, in effect, a single choke having the shape of the original core.
  • a wincing machine comprising means for supporting a curved magnetic core, means for winding a filament around a portion of the core which portion is located at a predetermined position relative to a base supporting the winding means, and means for moving a core supported by the support means along a curved path through that predetermined position.
  • FIG. 1 shows in perspective a socket adaptor 10 employing a toroidal choke of a type that can advantageously be made by the process of the present invention, with a typical fluorescent bulb of one type, shown by way of example only, in place in the adapter to illustrate the use of the latter.
  • the adapter 10 has a one-piece housing 12, which in the embodiment shown has a cylindrical main portion 14 and depending therefrom a cylindrical base portion 16.
  • a recess 18 formed in the top of the main portion 14 of the housing is shaped to detachably receive the base of the bulb 20.
  • the bulb 20 shown illustratively is a fluorescent unit having a U-shaped glass envelope in which light is fluorescently generated.
  • Both ends of the envelope are mounted on a base which has the shape of a T as seen from the side, and from the arms of which extend downward two electrical connector pins.
  • the recess 18 is shaped to receive substantially the entire base of the type of bulb for which the adapter in question is designed.
  • the ballast choke used with fluorescent and other types of bulbs is provided in the cylindrical portion 14 of housing 12, and in the adapter shown in Figure 1 is manufactured in the shape of a torus surrounding the recess 18.
  • the starter and capacitor for the electrical circuitry of the adapter 10 are preferably housed in the cylindrical base 16, which is provided with a cylindrical electronically conductive sleeve 22 fitted over and secured in any suitable fashion to the lower end of the cylindrical base 16.
  • the sleeve 22 has on its external surface threads to permit the adapter 10 to be screwed into a standard screw socket of thestype used with incandescent lamps.
  • the sleeve 22 serves to achieve electrical contact with such a socket.
  • An additional electrical contact 24 is provided at the lower tip of the cylindrical base 16, protruding through an aperture in sleeve 22, from the conductive material of which it is spaced. In use, contact 24 is in electrical contact with the other contact of such a socket.
  • the recess 18 is formed with holes for receiving the connector pins of the bulb 20, in which holes are provided contact pieces 21 to make electrical contact with the pins.
  • the electrical connections of the circuit elements described are well known to those skilled in the art.
  • the external threaded sleeve 22 is connected to the winding of the choke, the other end of which is connected to a contact piece 21 that received one of the connector pins of the bulb 20.
  • the other connector pin is received in engagement with a similar contact piece 21, which is connected to one terminal of each of the capacitor 23 and the starter 25.
  • the other terminal of the capacitor and the starter is connected to tip contact 24 on the exterior of the housing 12.
  • Tne toroidal ballast cnoke 30 used in the socket adapter of Figure 1 is shown in Figures 2 through 4 and comprises conductive windings 32 on two magnetic cores 34, each of which in the embodiment shown defines approximately a hemi-torus.
  • Each winding 32 is insulated from its respective core 34 by a layer of insulative material 36, which, as can be seen from the figures, does not extend all the way to either free end of the core 34. The reason for this feature is explained below.
  • toroidal cores for ballast chokes in the past has been the difficulty of manufacturing toroidal chokes reliably and with reasonable economy.
  • the illustrated choke lends itself readily to simple, reliable and inexpensive manufacture (see Figures 5 through 10).
  • a toroidal core of a suitable conventional magnetic material is provided.
  • a steel tape-wound core is suitable.
  • the toroidal core 34A is provided with a coating 36 of an electrically insulative material, which.covers the top, bottom, inner and outer surfaces of the torus. However, only one surface, for example the inner surface 38 or perhaps better the outer surface is completely covered by coating 36 around the entire circumference of the torus.
  • the other three surfaces are covered entirely except for two locations 40, preferably diametrically opposed, at which the core is left completely exposed except on the inner surface 38, or the outer surface, as the case may be. If desired, the core can be left exposed at 40 on all surfaces.
  • the insulative layer 36 is preferably provided by means of injection molding, although any other suitable manner of formation can be substituted according to convenience.
  • the most preferred method of forming the insulative coating 36 is by injection molding the insulative material, which may suitably be nylon purely by way of example, around the core in a mold shaped to leave the exposed areas 40 at the desired locations.
  • an alternative method is to pour the material into an open-topped mold with the core inside.
  • the mold 64 is made of a flexible material such as silicone, by way of example, and is flexed by any suitable means to release the core 34A and insulative . layer from the mold after setting of the insulative material.
  • An example of such a mold is shown schematically in Figures 6 and 7, in which the mold portions 41 for forming exposed areas 40 are visible. The portions 41 also support the core above the bottom of the mold. If injection molding is used, as is preferred, the mold used will be similar to that shown in Figures 6 and 7 with modifications clear to those in the art.
  • the insulative layer can be provided by dipping the original core into a bath of the insulative material, drying the resulting layer, for example in an oven, and blowing off excess liquid. After the cutting, dust of°the insulative material is blown onto the core while the latter is at an elevated temperature, to round the edges to prevent damage to the winding when the latter is formed.
  • the toroidal core is then cut in two through the exposed locations 40, resulting in two hemi-toroidal cores 34 as shown in Figure 3.
  • the cutting is preferably effected by means of a milling machine, which:has been found to do the cutting efficiently and with relatively low heat production, but any other method desired can be substituted and is within the scope of the invention, considered most broadly.
  • Each of the cores 34 is then separately provided with its respective winding 32. Because each of the cores 34 has the shape (as seen from above) of a circular arc, i.e., has a center line that defines a semi-circle or other portion of a circle, the windings can be applied in a very simple and economical fashion.
  • the arcuate core 34 is supported by being gripped at one end, and is rotated in the plane of the arc about the axis defining the center of the arc, viz., along the length of the core itself. As this movement is carried out, a wire is wrapped around the core, producing the desired winding 32.
  • the ends of the wire 50 are secured during the winding process in any suitable fashion within the ordinary skill in the art. After the windings 32 have been wrapped, the ends thereof are permanently secured in place by known expedients to provide two hemi-toroidal chokes. If desired, the cores of the two hemi-toroidal chokes can also be joined, by fish paper or other suitable known materials, to form a complete torus again.
  • the preferred emodiment 60 of the winding machine preferably used in carrying out the process of the invention comprises as its basic elements a support device 62 for supporting a curved, especially a hemi-toroidal, magnetic core 34, means 66 for winding a wire 50 around a portion of core 34 located at a predetermined position 68 relative to a base 69 on which the winding means is mounted, and means 70 for moving the core 64 supported by the support device 62 along a curved path (indicated by the broken line 72 in Figure 10).
  • the path 72 has the same shape as the portion of the core 34 on which a winding is to be formed.
  • the core is hemi-toroidal, as is path 72.
  • the support 62 comprises a gripper mounted on vertical bar 74, which is mounted on a horizontal bar 76 that constitutes part of the core movement means 70, as described below.
  • the gripper comprises a first bar 78 fixed to bar 74, and a second, L-shaped bar 80 secured to bar 78 in such a manner as to be movable along the length of the latter, as indicated by arrow A in Figure 9.
  • bar 80 can be secured to bar 78 by means of a screw 82 passing through a slot 84.
  • Loosening screw 82 permits bar 80 to bdr-moved in the direction of arrow A to release an object held between bars 78 and 80 or to grip an object therebetween. Tightening of screw 82 secures a gripped object in place.
  • one end of the core 34 is releasably clamped in this fashion between bars 78 and 80.
  • the winding device 66 comprises an arm 90 having one end mounted on a base 92 for rotation about a horizontal axis. Wire is drawn from a supply thereof (not shown), through the hollow interior of the arm 90 and out through an aperture 94 provided at the free end of the arm 90. The free end of the wire 50 is secured by any suitable known means to one end of the core, preferably the end gripped by the support 62. Rotation of the arm 90 by a motor system indicated schematically as block 96 winds the wire around the portion of the core located at position 68.
  • the support 62 is rotated about a vertical axis 98, while the arm 90 is rotating, to cause the portion of the core to be wound, to pass through position 68 to receive the wire from the arm 90.
  • bar 76 has one end supporting vertical bar 74 and the other end mounted for rotation about vertical axis 98.
  • the length of bar 76 substantially equals the radius of curvature of the hemi-toroidal core.
  • the motor system 96 powers the motion of bar 76.
  • the motor system 96 includes means, within the skill in the art, to enable movement of bar 76 in either direction about axis 98.
  • the linear density (by which is meant herein the number of turns per unit length of core) of the winding formed on the core is determined, other factors being equal, by the ratio of the rotational speed of arm 90 and the speed with which the core movement 76 is rotated about axis 98. While this ratio can be permanently built into the machine, it is preferable to make it variable, to render the machine capable of use not only for forming windings of different linear densities on cores of a given size and shape but also for providing windings on cores of different sizes or shapes or both.
  • Such control can be provided in several ways.
  • the motor system 96 can comprise two independently controllable motors at least one of which is variable in speed and reversible.
  • Another approach is to use a single motor, which can be a variable-speed motor, and a variable-ratio system of camming and gearing or the equivalent.
  • a numerical control system can be provided if desired to control motor speed(s) and starting and stopping points for the respective movements of arm 90 and of bar 76. Suitable control systems and gearing systems and the like are within the ordinary skill in the pertinent arts.
  • the substantially radially symmetric design of the choke 30 is not essential to the invention. Less compact, but still practical, variations can be adopted depending upon the design convenience and esthetic considerations.
  • the choke may be not only strictly toroidal but annular, i.e., polygonal or oval, or have other configurations.
  • the two exposed portions 40 of the original toroidal core be diametrically opposite, but that location makes cutting the core into two pieces especially easy, and the winding process is simplified by making the two pieces of the original core substantially the same size and shape.
  • either or both of the two cores 34 into which the original core is cut may, if desired, define less than 180 degrees of a circle, if the resulting manufacturing complexities are acceptable. Similarly, one core may be cut to less than 180 degrees while the other is cut to more than 180 degrees.
  • the division of the original toroidal core into two pieces is preferably done after the provision of the insulative layer, and this sequence is necessary with a tape-wound core to preserve it intact.
  • the reverse order is also within the scope of the invention, however.
EP85309051A 1984-12-13 1985-12-12 Verfahren zur Herstellung einer ringförmigen Vorschaltdrossel und Vorrichtung zur Durchführung dieses Verfahrens Withdrawn EP0188095A1 (de)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US68112084A 1984-12-13 1984-12-13
US68149384A 1984-12-13 1984-12-13
US681493 1984-12-13
US681120 1991-04-05

Publications (1)

Publication Number Publication Date
EP0188095A1 true EP0188095A1 (de) 1986-07-23

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EP85309051A Withdrawn EP0188095A1 (de) 1984-12-13 1985-12-12 Verfahren zur Herstellung einer ringförmigen Vorschaltdrossel und Vorrichtung zur Durchführung dieses Verfahrens

Country Status (4)

Country Link
EP (1) EP0188095A1 (de)
JP (1) JPS61185911A (de)
CN (1) CN85109520A (de)
AU (1) AU5121485A (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997006540A1 (fr) * 1995-08-04 1997-02-20 Liaisons Electroniques-Mecaniques Lem S.A. Dispositif de bobinage pour former une bobine electrique sur un circuit magnetique a entrefer
DE10159112A1 (de) * 2001-12-01 2003-06-18 Hella Kg Hueck & Co Zündtransformator für eine Gasentladungslampe in einem Kraftfahrzeug
WO2004057629A3 (en) * 2002-12-20 2004-08-12 Wellington Drive Technologies Electrodynamic machine
WO2008082805A2 (en) * 2006-12-27 2008-07-10 General Electric Company Lamp transformer assembly
US8697717B2 (en) 2002-03-13 2014-04-15 Janssen Pharmaceutica N.V. Inhibitors of histone deacetylase

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4699184A (en) * 1986-05-15 1987-10-13 Kuhlman Corporation Apparatus and method for fabricating a high voltage winding for a toroidal transformer
CN103746486A (zh) * 2014-01-27 2014-04-23 衣广津 板条型阻流圈
CN109509632B (zh) * 2018-11-26 2020-10-30 江阴市星火电子科技有限公司 一种绕制开口式线包的排线架
CN109767908B (zh) * 2018-11-26 2020-12-29 江阴市星火电子科技有限公司 一种开口式工件绕线机

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE479292C (de) * 1925-12-03 1929-07-15 Aeg Verfahren zur Herstellung von Induktionsspulen, vorwiegend fuer Fernsprechzwecke
FR862834A (fr) * 1939-01-14 1941-03-17 Lignes Telegraph Telephon Perfectionnements aux bobines électriques
US2773651A (en) * 1952-11-13 1956-12-11 Western Electric Co Coil winding apparatus
US2865086A (en) * 1953-03-16 1958-12-23 Western Electric Co Method of making a toroidal magnetic device
US3032729A (en) * 1957-05-16 1962-05-01 Phillips Petroleum Co Temperature stable transformer
DE1154868B (de) * 1960-08-29 1963-09-26 Telefunken Patent Verfahren zur Isolierung des Kernes und der Wicklung von Ringkernspulen oder -uebertragern, insbesondere der Nachrichten- und Messtechnik, mittels vorzugsweise thermoplastischer Isolierstoffolien
US3477051A (en) * 1967-12-26 1969-11-04 Ibm Die casting of core windings

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE479292C (de) * 1925-12-03 1929-07-15 Aeg Verfahren zur Herstellung von Induktionsspulen, vorwiegend fuer Fernsprechzwecke
FR862834A (fr) * 1939-01-14 1941-03-17 Lignes Telegraph Telephon Perfectionnements aux bobines électriques
US2773651A (en) * 1952-11-13 1956-12-11 Western Electric Co Coil winding apparatus
US2865086A (en) * 1953-03-16 1958-12-23 Western Electric Co Method of making a toroidal magnetic device
US3032729A (en) * 1957-05-16 1962-05-01 Phillips Petroleum Co Temperature stable transformer
DE1154868B (de) * 1960-08-29 1963-09-26 Telefunken Patent Verfahren zur Isolierung des Kernes und der Wicklung von Ringkernspulen oder -uebertragern, insbesondere der Nachrichten- und Messtechnik, mittels vorzugsweise thermoplastischer Isolierstoffolien
US3477051A (en) * 1967-12-26 1969-11-04 Ibm Die casting of core windings

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997006540A1 (fr) * 1995-08-04 1997-02-20 Liaisons Electroniques-Mecaniques Lem S.A. Dispositif de bobinage pour former une bobine electrique sur un circuit magnetique a entrefer
DE10159112A1 (de) * 2001-12-01 2003-06-18 Hella Kg Hueck & Co Zündtransformator für eine Gasentladungslampe in einem Kraftfahrzeug
US8697717B2 (en) 2002-03-13 2014-04-15 Janssen Pharmaceutica N.V. Inhibitors of histone deacetylase
US9150560B2 (en) 2002-03-13 2015-10-06 Janssen Pharmaceutica Nv Inhibitors of histone deacetylase
US9556161B2 (en) 2002-03-13 2017-01-31 Janssen Pharmaceutica Nv Inhibitors of histone deacetylase
WO2004057629A3 (en) * 2002-12-20 2004-08-12 Wellington Drive Technologies Electrodynamic machine
WO2008082805A2 (en) * 2006-12-27 2008-07-10 General Electric Company Lamp transformer assembly
WO2008082805A3 (en) * 2006-12-27 2008-12-04 Gen Electric Lamp transformer assembly
US7746211B2 (en) 2006-12-27 2010-06-29 General Electric Company Lamp transformer assembly

Also Published As

Publication number Publication date
CN85109520A (zh) 1986-09-03
JPS61185911A (ja) 1986-08-19
AU5121485A (en) 1986-06-19

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