US3726005A - Method of manufacturing flat-wire field coils - Google Patents

Method of manufacturing flat-wire field coils Download PDF

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Publication number
US3726005A
US3726005A US00125190A US3726005DA US3726005A US 3726005 A US3726005 A US 3726005A US 00125190 A US00125190 A US 00125190A US 3726005D A US3726005D A US 3726005DA US 3726005 A US3726005 A US 3726005A
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US
United States
Prior art keywords
coil
particles
method defined
last turn
thermoplastic
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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 - Lifetime
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US00125190A
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English (en)
Inventor
E Prostor
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.)
ISKRA LAVOD AVTOMATIZACIJO ZDRUZENEM POD ISKRA YU
ISKRA ZAVOD ZA AVTOMATIZ
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ISKRA ZAVOD ZA AVTOMATIZ
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Application filed by ISKRA ZAVOD ZA AVTOMATIZ filed Critical ISKRA ZAVOD ZA AVTOMATIZ
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Publication of US3726005A publication Critical patent/US3726005A/en
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Expired - Lifetime legal-status Critical Current

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/325—Windings characterised by the shape, form or construction of the insulation for windings on salient poles, such as claw-shaped poles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling

Definitions

  • ABSTRACT A method of manufacturing flat-wire field coils for an electric machine, especially a starter for an internal combustion engine, wherein one metallic surface only of a metal strip is coated with an adhesive lacquer and particles of rigid insulating material are disposed upon this surface and adhere to the adhesive lacquer thereof. Non-adherent particles are removed and the metal strip is coiled so that the adherent particles space apart the successive turns. The last turn is fixed to the coil which is heated and contacted with a suspension of thermoplastic or duroplastic resin powder to form a sheath around the coil. The coil is then bent to the desired shape of the field coil.
  • the present invention relates to a method of manufacturing fiat-wire field coils intended to be mounted into electric machines, particularly into starters of intemal-combustion engines.
  • the aim of the invention is to avoid these disadvantages and replace the paper insulation by another insulating material, whereby other stages of coil manufacture are also improved.
  • this object is achieved in the manner that on its broadside the flat wire is covered by an insulating material preferably of mineral origin, such as quartz (silica), corundum or the like, with particles of a definite thickness of 100, 150 or 200 pm, and these particles are fixed to the flat wire because of a previously applied adhesive.
  • the layer of the insulating particles adhering defines the distance between the turns.
  • the coil is temperature-resistant, which makes it possible to anneal it by joulean heat after coiling in order to remove the internal stresses arising in the copper wire during coiling.
  • Advantageous is electric annealing of a half of the last external turn. Thereby the coil will maintain its shape and the prior systems of fixing the last turn becomes superfluous.
  • FIG. 1 shows the application of insulating particles to the fiat wire
  • FIG. 2 shows the coil after accomplished coiling, with the fixed last turn
  • FIG. 3 shows the coil with the electrodes applied for joulean heating of a half of the last external turn, in order to reduce internal stresses
  • FIG. 4 shows the coil after application of the solidifying and insulating sheath
  • FIG. 5 is a sectional elevation of the coil before the final fashioning
  • FIG. 6 is a sectional elevation of the coil after the final fashioning.
  • spacing particles 13 of an insulating mineral material such as quartz (silica), corundum, ceramics, of a definite size of 100, 150 or 200 um are scattered as this is shown in the right part of FIG. 1.
  • the particles first impinged adhere to the wire surface while the rest can be removed, e.g., by blowing.
  • this spacing insulating layer is applied only to the wire parts of definite and necessary length so that the ends of the coil do not show any insulation.
  • Coiling of the coils proceeds according to known methods; for the securing of the last turn there exist two possibilities.
  • the last turn can be held by a cord 14 (FIG. 2) having such a heat resistance that it 5 withstands the heating of the coil during its insulation.
  • Sheathing of the coil proceeds according to known methods by thermoplastics, preferably polyamides, or by duroplastics, preferably powdery epoxy resins, in a bath with suspended powdery particles or by sprinkling in an electrostatic field or without a field as well as with simultaneous or subsequent sintering and in a given case with additional heat treatment.
  • the sheath 20 comprises the coil 21 itself and the leadins 22 without the terminations which must remain non-insulated (FIG. 4).
  • the coil is advantageously preheated by joulean heat which renders possible maintenance of the temperature required also during the application of the insulating material of the sheath.
  • thermoplastic powders are used, whereby a coil with such a sheathing has only to be cooled down after accomplished sintering. With a proper treatment, the insulating material 20 penetrates deeply between the turns 23 so that the spacing layer 19 is partially impregnated (FIG. 5), whereby a subsequent bending of the coil to the shape required is possible without damage (FIG. 6).
  • a method of making a flat-wire field coil for an electric machine comprises the steps of:
  • thermoplastic selected from the group which consists of teflon, polyamides and pentones.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Organic Insulating Materials (AREA)
  • Insulating Of Coils (AREA)
  • Manufacture Of Motors, Generators (AREA)
US00125190A 1970-03-20 1971-03-17 Method of manufacturing flat-wire field coils Expired - Lifetime US3726005A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
YU70870 1970-03-20

Publications (1)

Publication Number Publication Date
US3726005A true US3726005A (en) 1973-04-10

Family

ID=25551086

Family Applications (1)

Application Number Title Priority Date Filing Date
US00125190A Expired - Lifetime US3726005A (en) 1970-03-20 1971-03-17 Method of manufacturing flat-wire field coils

Country Status (3)

Country Link
US (1) US3726005A (OSRAM)
DE (1) DE2032986B2 (OSRAM)
FR (1) FR2084962A5 (OSRAM)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4433474A (en) 1981-10-08 1984-02-28 Electric Power Research Institute, Inc. Amorphous magnetic core and process for manufacturing to improve efficiency
US5837940A (en) * 1995-05-15 1998-11-17 Moncrieff; J. Peter Conductive surface and method with nonuniform dielectric
FR2825535A1 (fr) * 2001-05-31 2002-12-06 Valeo Equip Electr Moteur Procede de fabrication d'un rotor
US6544056B1 (en) * 1998-09-24 2003-04-08 Eads Deutschland Gmbh Temperature-controlled wire support
US6660412B2 (en) * 2001-03-15 2003-12-09 Waseem A. Roshen Low loss, high frequency composite magnetic material and methods of making the same
US6686822B2 (en) 2000-04-19 2004-02-03 General Electric Company Powder coated generator field coils and related method
US20150229175A1 (en) * 2014-02-13 2015-08-13 Sanyo Denki Co., Ltd. Stator, method for manufacturing stator, and motor

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1751971A (en) * 1929-10-11 1930-03-25 Acme Wire Company Process for producing electric coils
US3037885A (en) * 1960-12-27 1962-06-05 Gen Electric Method of insulating an electrical coil
US3145127A (en) * 1961-06-28 1964-08-18 Gen Electric Method of insulating electrical components, such as small electric motors
US3418710A (en) * 1963-05-08 1968-12-31 Westinghouse Electric Corp High temperature magnetic cores and process for producing the same
US3440587A (en) * 1966-02-21 1969-04-22 Dow Corning Electrical induction apparatus construction
US3518755A (en) * 1967-07-03 1970-07-07 Anaconda Wire & Cable Co Method of forming electrical coils

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1751971A (en) * 1929-10-11 1930-03-25 Acme Wire Company Process for producing electric coils
US3037885A (en) * 1960-12-27 1962-06-05 Gen Electric Method of insulating an electrical coil
US3145127A (en) * 1961-06-28 1964-08-18 Gen Electric Method of insulating electrical components, such as small electric motors
US3418710A (en) * 1963-05-08 1968-12-31 Westinghouse Electric Corp High temperature magnetic cores and process for producing the same
US3440587A (en) * 1966-02-21 1969-04-22 Dow Corning Electrical induction apparatus construction
US3518755A (en) * 1967-07-03 1970-07-07 Anaconda Wire & Cable Co Method of forming electrical coils

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4433474A (en) 1981-10-08 1984-02-28 Electric Power Research Institute, Inc. Amorphous magnetic core and process for manufacturing to improve efficiency
US5837940A (en) * 1995-05-15 1998-11-17 Moncrieff; J. Peter Conductive surface and method with nonuniform dielectric
US6544056B1 (en) * 1998-09-24 2003-04-08 Eads Deutschland Gmbh Temperature-controlled wire support
US6686822B2 (en) 2000-04-19 2004-02-03 General Electric Company Powder coated generator field coils and related method
US6778053B1 (en) * 2000-04-19 2004-08-17 General Electric Company Powder coated generator field coils and related method
US6660412B2 (en) * 2001-03-15 2003-12-09 Waseem A. Roshen Low loss, high frequency composite magnetic material and methods of making the same
FR2825535A1 (fr) * 2001-05-31 2002-12-06 Valeo Equip Electr Moteur Procede de fabrication d'un rotor
US20150229175A1 (en) * 2014-02-13 2015-08-13 Sanyo Denki Co., Ltd. Stator, method for manufacturing stator, and motor
US10312763B2 (en) * 2014-02-13 2019-06-04 Sanyo Denki Co., Ltd. Stator, method for manufacturing stator, and motor
US10666108B2 (en) 2014-02-13 2020-05-26 Sanyo Denki Co., Ltd. Stator, method for manufacturing stator, and motor

Also Published As

Publication number Publication date
FR2084962A5 (OSRAM) 1971-12-17
DE2032986A1 (de) 1971-10-14
DE2032986B2 (de) 1972-06-29

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