US1815620A - Electrical induction coil and method of manufacture thereof - Google Patents

Description

G. E. HORN 1,815,620

ELECTRICAL INDUCTION COIL AND METHOD OF MANUFACTURE THEREOF July 21, 1931.

Filed Oct. 31, 1928 2 Sheets-Sheet l K HNVENTOR BY a ATTORNEY July 21, 1931. G HORN 1,815,629

ELECTRICAL INDUCTIQN COIL AND METHOD OF MANUFACTURE THEREOF Filed Oct. 31, 1928 2 Sheets-Sheet 2 BY 1 %WW4L ATTORNEY.

, Patented July 21,1931.

PATENT OFFICE UNITED STATES- GEORGE E. HORN, OF FORT WAYNE, INDIANA, ASSIGNOR- TO GENERAL CABLE COR-- PORATION, OF NEW YORK, N. Y., A CORPORATION OF NEW JERSEY ELEOTBICAEINDUCTION COIL AND METHOD OF MANUFACTURE THEREOF Application filed October 31, 1928.

This invention relates to improvements in electrical induct-ion coils and methods of manufacture thereof, more particularly to a unit coil having a primary and a secondary winding of very fine wire; such as coils usufrom which to conveniently make an induction coil, which pack consists of a winding formed of a multiplicity of layers, usually of a single length of wire. arranged in close spiral formation disposed in successive order, one layer superimposed upon another,

which winding preferably includes portions of the wire permanently placed toform, correspondingly, primary and secondary circuits, and initial and medial coiled portions transiently placed, whereby terminal connections may be expeditiously attached re spect-ively to the ends of those portions for said circuits. Further objects of the invention are to provide an expedient to assist artisans in selecting the ends of the wires of which primary and secondary circuits are formed in a coil pack, to thereby facilitate the application of terminal connections thereto; and to reduce the number of and simplify the mechanical and manual operations hitherto required in the manufacture of completed coils of the class described.

It has been found of advantage in the winding of coil units having primary and secondary circuits, to perform the entire winding with a single Wire in a continuous operation, and attach the terminal connections for the two circuits subsequently, because of acceleration of the winding operation. However, when the wires forming the coils are exceedingly fine, considerable difliculty has been experienced, in locating and drawing out the ends of the wires of which the circuits are formed to permit of the at tachment thereto of the terminal connections without disturbance of the permanent turns of the wire in said circuits. The present invention enables such advantage to be secured without the difficulty above referred to.

Serial No. 316,328.

struction illustrated in the accompanying drawings, in which:

I Fig. 1 is a perspective view of the unit coil completed and with its terminal connections attached; v

Fig. 2 is 'a perspective view of an unfinished coil pack showing the medial porgion of the wire partially withdrawn thererom;

Fig. 3 is a diagram of one end of the unfinished pack; and

Fig. 4 is a diagrammatical elevation projected from Fig. 3, a portion being broken away.

The illustrations of the invention, Figs. 3 and 4 are drawn upona disproportionate scale, the wire 5 forming the winding for the coil 6, appearing as magnified, and the number of layers 7 and 8 thereof being numerically less as compared with an actual structure embodying the invention, the diagrammatical form of illustration being resorted to for the sake of convenience in showing the relative positions of the several portions of the winding of the wire.

The pack 6 is initially formed by winding about a tubular core 9, a wire 5 of insulated wire in spiral formation in successive layers, one upon another, the layers 7 being first wound upon the core, there being introduced retaining members 10 during the winding operation whereby each layer is surrounded by a corresponding retaining member when completed. Said retaining membprs consist of strips of pliant insulating material, such as paper, each strip being of a size sufficient to extend completely around the layer, with its ends overlapping. The layers 7 are sulficiently numerous to form a primary circuit of such electrical characteristics as may be predetermined.

Upon the completion of the group of layers 7 there is wrapped thereon an indicating member 11 consisting of a paper strip of sufficient length to pass around the group several times, which strip is of a color contrasting sharply from that of the retaining members 10. As the member 11 is wrapped in place, the wire 5 is wound upon the indicat- 60 These objects are accomplished by the coning member spirally outward from the adjacent layer 7 so that a series of additional turns 12 of said wire are established in a plane beyond that of the adjacent ends'of the layers 7 and between the layers of the indicating member, the margin of which indicating member and those of the retaining members 10 extend outwardly beyond the ends of the permanent layers 7 and 8 of the wire. Upon the indicating member 11 is wrapped a second indicating member 13, also consisting of a paper strip of sufficient length to form several layers, the strip 13 being of a color distinctive from those of the retaining members and the other indicating member, and as the member 13 is wrapped in place, the wire 5 is wound thereon spirally inward so that a second series of addltional turns 14 are established between the layers of said second indicating member 13. The layers 8 are then wound in place, with a retaining member 10 interposed between each layer, and upon completion of the outermost of the layers 8 a covering 15 is applied to the pack to prevent disarrangement of the layers.

The completed winding of the wire in the pack is constituted of an initial removable portion consisting of a number of turns 16 that are wound so as to lay out beyond the general plane of the adjacent ends of the layers 7 and 8; and the innermost of the layers 7 is composed of permanently placed turns that are a continuation of the initial turns 16. The last turn 17 of the second of the la ers 7 which next overlies the innermost 0 said layers, is spaced inwardly from the general plane of the adjacent ends of the layers 7 and 8 so that the turns 16 of the initial portion of the winding, and those immediately adjacent thereto in the innermost layer 7, are relieved from pressure of the overlying turns of the wire. The initial turns 16 are yieldingly held in position temporarily by the overlying retaining member 10, and may readily be drawn outwardly from place and made accessible when required. Likewise, the last turn 18 of the second of the layers 8 that overlies the indicating member 13 is spaced inwardly from the general plane of the adjacent ends of the layers 7 and 8, so that the turns 12 and 14 of the medial portion of the winding are relieved from excessive pressure from the overlyin layers. Thus, the turns 12 and 14 are yiel ingly held in position temporarily between the layers of the indicating members and may readily be drawn outwardly from place and made accessible when required.

The winding throughout its various portions, as shown and described herein, is of a single continuous wire, the initial and medial portions being readily accessible and withdrawable, while the layers 7 and 8, for the primary and secondary circuits, are firmly'and ermanently retained in place within the pack.

The pack thus prepared is then transformed and a unit induction coil made therefrom, by unwinding from the pack the initial turns 16 to form one of the terminals 20 of the primary coil formed by the layers 7; the medial portion of the winding is unraveled from the pack and severed to form, respectively, the other terminal 21 for said primary coil, and one of the terminals 22 for the secondary coil that is composed of the layers 8; and the-extreme end portion of the outermost layer 8 is unwound sufiiciently to form the other terminal 23 for said secondary coil.

Each of said terminals 20, 21, 22 and 23, have attached thereto in the usual manner a corresponding terminal connection 20, 21', 22 and 23, which terminals with their attached connections are fixed u on the pack in spaced relation with each other by means of suitable adhesive anchor strips 24 and 25 as in the customary manner.

As the method by which the entire winding for the unit induction coil is performed with a single wire, the operation is more or less continuous and expeditious; and by incorporating in the pack the initial and medial removable surplus turns of the wire offset from permanent turns to form corres onding terminals for the primary and secon ary circuits, disarrangement of the permanent turns of the layers is obviated, inasmuch as the removable portions of the winding are retained temporarily in definite locations until their unraveling from the pack is required.

A feature of the invention consists in the inclusion in the pack of the indicating members 11 and 13 upon which the medial turns of the wire are wound. The two indicating members, difi'ering in color from each other and from the adjacent retaining members, enables the artisan when applying the terminal connections, to locate in the pack the medial removable turns without search.

Also, the retention within the pack of the initial and medial turns of the winding until required for the attachment of the terminal connections is of advantage, especially when the winding is of very fine wire, as disarrangement, entanglement, confusion and loss of the terminal ends of the coils are circumvented.

The invention may be applied with facility in the manufacture of units wherein the coils are composed of coarse wires, and the indicating mean-s may be constituted of a single strip, or of several strips spaced apart with insulating material (not shown) disposed therebetween should heavy insulation between the coils be desired. The function of the indicating member primarily is to temporarily sustain the medial portion of the wire in an accessible and easily located position in the embryonic member to guide the artisan when drawing said portion out from terminals for the coils without breaking thethe pack that it may be severed to provide terminals away from the permanent turns or otherwise disturbing the layers thereof.

Numerous other modifications in the construction and arrangement of the indicating member and other parts may be resorted to by the exercise of skill without departure from the spirit of the invention.

What I claim is 1. A pack from which to make an induction coil unit, containing a winding formed of a wire arranged in a multiplicity of permanent layers disposed in successive order,

one surrounding another, a number of remov able initial turns of the wire at the commencement of the first of said layers, a removable medial portion consisting of a number of additional turns of the wire, said initial and additional turns being accessibly disposed respectively in the pack out beyond the adjacent ends of the corresponding permanent layers to permit withdrawal thereof to provide corresponding terminals for the coils of said unit, and means included in said pack for supporting said initial turns in accessible position beyond the adjacent ends of the permanent layers.

2. A pack from which to make an induction coil unit, consisting of a wire wound in a series of layers, one surrounding another; indicating strips interposed between two adjacent intermediate layers of said series; and supporting strips interposed respectively between the other layers, said indicating strips being distinguishable from said supporting strips, a medial portion of said wire being entwined .with said indicating strips and accessibly supported therein beyond the ends of said layers to permit the withdrawal of several turns of wire, to provide corresponding terminals for the coils of said unit.

3. A pack from which to make an induction coil unit, consisting of a wire wound in a series of layers, one surrounding another; indicating strips interposed between two adjacent intermediate layers of said series; and an additional portion of said wire connecting. said intermediate layers supported by said indicating strips and accessibly disposed at one end of the pack beyond said layers to permit withdrawal of said portion to provide corresponding terminals for the coils of said unit.

4. A pack from which to make an induction coil unit, consisting of a wire wound in two series of layers connected b an additional portion of said wire that as numerous turns arranged in the pack beyond said layers; a supporting strip interposed between each layer and the layer adjacent thereto in each series; and an indicating means distinguishable from said supporting strips, disposed between said two series, said additional portion of the wire being related to said indicatng means so as to be supported and readily located and unraveled when required to provide corresponding terminals for the coils of said unit.

5. A pack from which to make an induction coil unit, consisting of a pack in which two permanent coils formed of a continuous wire are contained, there being an additional portion of said wire initially connecting said coils removably disposed in said pack beyond the adjacent ends of said coils, to be subsequen'ly located, drawn out and severed to provide a corresponding terminal for each of said coils.

6. A pack from which to make an induction coil unit in which member two coils formed of a continuous wire are permanently disposed, and in which one of the ends of said wire and a medial portion thereof between said coils are disposed in said member aside from said permanently disposed coils so as to be readily located, drawn out and severed to provide corresponding terminals for said coils.

7. A pack from which to make an induction coil unit, consisting of a winding formed of a continuous wire, two portions of which are each arranged in a multiplicity of permanent layers, one surrounding another, and supporting strips interposed between said layers respectively, the sides thereof extending beyond the ends of said layers, an initial portion of said Winding contiguous with the first layer thereof being yieldingly held in said pack by the extendmg part of the overlying strip beyond the ad acent ends of said layer, and a medial wound portion of said wire connecting the two first portions, and held yieldingly in said pack beyond the ends of the corresponding layers, said initial and medial ortions being accessibly disposed to permit ing drawn out and severed to provide corresponding terminals for said induction coil unit.

8. A pack from which to make an induction coil unit, consisting of a winding formed of a continuous wire, two portions thereof having each a series of permanent layers constituting a primary and a secondary coil, supporting strips interposed between said layers respectively, and two indicating strips of contrasting colors interposed between said coils, a medial portion of said winding connecting said coils removably supported by and accessibly disposed in said indicating strips beyond the ends of said coils whereby said medial portion may be readily located and drawn out to provide a corresponding terminal for each coil.

9. A pack from which to make an induction coil unit, consisting of a Winding to provide primary and secondary coils and a medial portion connecting said coils, and an indicating means interposed between said coils and extending outwardly therefrom, by which means said medial ortion is removably supported and accessi ly disposed beyond the corresponding ends of said coils, whereby said medial portion may be readily located and drawn out from the pack to provide a corresponding terminal for each coil.

10. The method of making an induction coil unit, consisting in preparing a pack by winding a continuous wire u on a core to form the primary and secon ary coils for said unit and with a removable medial rtion of the wire connecting said coils, an in terposing between the layers of each coil corresponding supporting strips, and between said coils indicating strips, distinguishable from said su rting strips, in such manner as to remova y sup ort said medial portion in the pack beyond t e adjacent ends of said coils in an accessible position; subsequently drawing out said medial ortion and ends of said wire from said mem er; and severing said medial portion, to provide terminals for said primary and secondary coils.

11. A pack from which to make an induction coil unit, consisting of a wire wound to 1provide primary.and secondary coils, each aving numerous layers; retaining strips between said layers extending beyond the ends thereof, and a medial wound portion connectingsaid coils removably disposed in the pack beyond the ends of the ad acent layers, the layer next succeeding the layer connected wlth said removable portion terminating at a point spaced inwardly from the ends of the overlying layers.

12. As a new article of manufacture, a multi-layer coil windin formed from a continuous wire, and in WlllCh the layers are substantially co-extensive and are separated from each other b strips of insulating material which exten beyond the edges of the coil winding, characterized by the fact that at least one of the coil layers is wider than and extends beyond the other layers, whereby without disturbing adjacent coil layers several turns of wire may readily be withdrawn from the edge-of the wider coil layer to provide a terminal for the coil winding.

13. A pack from which to make an induction coil unit, consisting of a wire wound to provide primary and secondary coils each composed of numerous permanently disposed layers of the wire, and having portions removably disposed in the pack located therein axially beyond the ends of the adjacent layers, the layer in each coil next succeeding the corresponding removable portion being offset inwardly from the overlyin layers.

14. A pack from which to ma e a coil unit, consisting of a wire wound to provide a coil having a series of layers each composed of permanently placed turns; retaining strips between said la ers; and a removable wound portion of sai wire disposed in the pack connecting the ends of two adjacent layers,

the layer next succeeding the connected layers being ofi'set inwardly beneath the correspondin ends of the overlying layers of the coil to t ereby relieve said removable portion from pressure of the overlying turns and to permit withdrawal of said portion from the pack.

15. An electrical coil structure havin numerous wound layers of wire the en s of which layers terminate substantially in a common plane extending at ri ht angles to the axis thereof, and two ad jacent interposed layers connected at one end with each other that are characterized by terminating with respect to their connected ends at a point spaced axially from the plane of the coriesponding ends of the former layers.

16. An electrical coil structure formed from a continuous wire in which are included primary and secondary coils each having numerous overlying layers and an' additlonal coil extending out beyond the ends of adjacent layers of said primary and secondary coils and connecting said prima and secondary coils; supporting strips disposed between the layers of said primer and secondary coils; and additional strlps, distinguishable from the first named strips, supporting said additional coil in a location adj acient the connected ends of the first named cm s.

17 The method of making an electrical coil structure which comprises winding a coil in successive layers, interposing supporting strips between the layers, interposing distinctive indicating means between medial layers of said coil, extendin one of the medial layers adjacent said in icating means out beyond the ends of adjacent layers, and subsequently drawin out the extended ortion of the said medial layer to rovi e a terminal intermediate the ends 0 the coil windin 18. T e method of making an electrical coil structure which comprises winding a coil in successive layers, interposing supporting strips between the layers, interposing distinctive indicating means between medial layers of said coil, extending one of the medial layers adjacent said Indicating means but beyond the ends of adjacent layers, supporting the extended portion of the said medial layer by said indicating means, subsequently drawin out the extended portion of the said medial ayer, and severing the extended portion to provide coil terminals intermediate the ends of the coil windin 19. The method of making an electrical coil structure which com rises winding a continuous wire in a plurality of overlying la ers to provide primary and secondary coi s, inserting supporting strips longer than the coil layers between said layers during the winding operation, and, during the winding operation, winding a plurality of turns of wire connecting said primary and secondary coils in the supporting strips out beyond the ends of adjacent coil layers, whereby the said turns subsequently may be readily withdrawn from the end of the coil structure to provide coil terminals.

In testimony whereof I afiix my signature.

GEORGE B. HORN.

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