US3771086A - Electric coil consisting of a continuous strip-shaped conductor - Google Patents

Electric coil consisting of a continuous strip-shaped conductor Download PDF

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Publication number
US3771086A
US3771086A US00177999A US3771086DA US3771086A US 3771086 A US3771086 A US 3771086A US 00177999 A US00177999 A US 00177999A US 3771086D A US3771086D A US 3771086DA US 3771086 A US3771086 A US 3771086A
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Prior art keywords
conductor
strip
coil
electric coil
terminals
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US00177999A
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English (en)
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P Poulsen
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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
    • 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
    • H01F41/10—Connecting leads to windings
    • 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 3 Claims, 4 Drawing Figures ELECTRIC COIL CONSISTING OF A CONTINUOUS STRIP-SHAPED CONDUCTOR This invention relates to an electric coil consisting of a continuous flat strip-shaped conductor wound together with one or more layers of insulating material. The purpose of the latter is to insulate adjacent convulutions from each other and to insulate the edges of the metal strip from contact with conductive parts in the vicinity of the coil.
  • the insulating material could be a separate film or an insulating layer attached to the conductor.
  • a comparatively wide strip is wound into an elongated coil which is thereafter cut into shorter units by means of knives that are pressed against the rotating coil.
  • Normally coils made in this way are not immediately useable because burrs are often formed along the edges of the metal strip during the cutting thus short-circuiting adjacent turns and this calamity is met by a subsequent etching process wherein the individual coils are submerged completely or partly into an acid. Through this process possible burrs are removed along with the outermost edges of the metal foil so that the insulating film protrudes somewhat over the edges of the conductive strip whereby an effective insulation of the coil ends is secured.
  • the coils are wound one by one by using a strip of insulating film which is a little wider than the metal foil strip and winding the strips concentrically so that the insulating film is protruding over the edges of the metal strip thereby ensuring the above mentioned insulating effect.
  • a different problem in the making of strip wound coils is the making of reliable terminal connectors and possible intermediatetap leads.
  • the metal foil is often thin and too weak to be used as a terminal connector itself and the litterature describes a large number of methods for the making of terminal leads and attaching these to the foil strip.
  • the material is copper it is a comparatively simple procedure to solder a wire or strip connector locally onto the conductor where a tap or terminal is required, but when aluminum foil is used it is difficult to get a reliable electrical contact by soldering due to the oxidation of the metal during the process. Accordingly, often mechanical methods are used for the attachment of terminal strips but as every joint is an inherent weakness their number is preferably reduced to a minimum.
  • a further object of the present invention is to provide for a coil wherein the outlined difficulties are eliminated and by which tightly wound coils can be made from very thin foil and yet any number of mechanically strong taps and terminals can be carried out without introducing any joints at all.
  • a still further object of the invention is to provide for a winding process which is rapid and free of soldering or welding operations. Further, the invention is related to an apparatus for carrying out the process.
  • FIG. 1 is the main elements of a winding apparatus for coils according to the invention, 7
  • FIG. 2 schematically, a strip conductor produced by unwinding a coil according to the invention
  • FIG. 3 a detail of a tap lead from a coil according to the invention.
  • FIG. 4 a modification of a tap lead.
  • the storage coil 1 contains metal foil having a width approximately equal to the width of the coil to be produced but substantially thicker than the thickness of the section of conductor required.
  • the required cross section can be 5 mm needing a thickness of 0.1 mm or 2 mm which must be 0.04 mm thick.
  • From the storage coil the strip is guided between two rollers 2 and 3 which are mounted rotatably in bearing blocks, not shown, and provided with an arrangement enabling the gap between the rollers to be varied and selected quickly and accurately anywhere within a range of for instance 0 to 1 mm.
  • the roller 2 is fitted onto one of the output shafts of the gearbox 4 and roller 3 to the other output shaft via an arrangement of universal joints to allow for the above mentioned variation of the distance between the rollers.
  • the gearbox 4 is connected with a motor, not shown, whereby the rollers can be brought into rotation with the same speed but in mutually opposed directions, as indicated by the arrows.
  • the bobbin 5 is fitted to the shaft of an electric torque motor 6 which could also be an over-running, torque adjustable coupling driven by a normal fixedspeed motor.
  • the storage coil 7 contains insulating film, which is a little wider than the metal strip, and the arrangement is provided with an adjustable brake, not shown, by means of which the film tension can be adjusted within a suitable range.
  • the above components are arranged in such manner that the torque motor 6 tends to turn the bobbin in the direction indicated by the arrow, but as the roller gap is less than the thickness of the metal strip, the bobbin is prevented from turning unless the rollers are operating.
  • the gearbox S is self-locking so that the rollers will only rotate when the drive motor is running and the HP of this motor is selected so that the rpm of the rollers may be governed, for example by means of a speed control device, without being affected appreciably by the tension in the strip due to the torque motor 6.
  • the torque provided by 6 must be enough to overcome the tension in the insulating film within its adjustable range.
  • the effect of the above arrangement is that the rpm of the roller motor decides the winding speed, the torque yielded by the torque motor 6 decides the tension in the metal foil strip and the setting of the brake for the insulating film decides the tension of the film.
  • FIG. 2 illustrates a metal foil strip produced by unwinding a coil according to the invention and indicates how the mechanism is used during the winding process.
  • the roller gap is held at for example 0.4 mm for a moment and the starting end of the strip is thus reduced from 0.5 to 0.4 mm.
  • the strip is slit as shown at 8 whereafter the narrow lead is bent free of the strip so that it protrudes from the coil parallel to its axis.
  • the roller gap is reduced to the predetermined value, for example 0.04 mm and the first part of the coil is wound until point 10 is reached immediately prior to the desired tap where the gap is again raised to 0.4 mm while a length of strip sufficient for the tap lead is passing the rollers.
  • the terminal is made like shown at 8 and the gap again reduced to 0.04 or for example 0.06 mm in case a larger cross section is required in the last part of the coil. Now the winding is continued till the gap is again raised to 0.4 mm at 12 and the coil completed with the terminal 13 prior to the normal banding with an insulating sheet.
  • FIG. 3 is a detail of the strip wherein the narrow lead has been stretched lightly at 14 by means of a hammer or by pressing with a special tool thereby bending the lead free of the strip until it is perpendicular to the tape axis.
  • the advantage by this method is that a locally doubled thickness is avoided as it is the case when the strip is bent over as shown in FIG. 4.
  • this version is normally faster to carry out and in some cases preferable.
  • terminals from the first and final turn plus any number of taps in between can be made in a fast and simple procedure without joints along the way and thereby inevitable variations in quality.
  • the cross sectional area of the terminal leads can easily be held larger than or equal to the conductor section in the rest of the coil and the comparatively narrow lead strips can be easily handled and due to their thickness clamped into connector blocks etcetera without particular caution.
  • the terminals will have a good mechanical strength and it is often valuable that several different section areas can be used in the same coil without changes of strip during the winding. It is also an advantage that the necessary range of foil thicknesses held in stock can be reduced to a few, each of which representing a stepless range of conductor thicknesses.
  • an electric coil consisting of a flat strip-shaped conductor wound together with one or more layers of insulating material and containing two or more sections with taps or terminals, the thickness of the conductor being constant for each section and varying from section to section in accordance with the required cross sectional area in the section said taps or terminals and said conductor being of single unit construction in the sections of larger cross sectional area.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Windings For Motors And Generators (AREA)
US00177999A 1970-09-08 1971-09-07 Electric coil consisting of a continuous strip-shaped conductor Expired - Lifetime US3771086A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DK459470 1970-09-08

Publications (1)

Publication Number Publication Date
US3771086A true US3771086A (en) 1973-11-06

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ID=8134961

Family Applications (1)

Application Number Title Priority Date Filing Date
US00177999A Expired - Lifetime US3771086A (en) 1970-09-08 1971-09-07 Electric coil consisting of a continuous strip-shaped conductor

Country Status (13)

Country Link
US (1) US3771086A (es)
AT (1) AT310895B (es)
BE (1) BE772357A (es)
CA (1) CA943197A (es)
CH (1) CH529431A (es)
DE (1) DE2144386A1 (es)
ES (1) ES203618Y (es)
FR (1) FR2107385A5 (es)
GB (1) GB1356325A (es)
NL (1) NL7112309A (es)
NO (1) NO130803C (es)
SE (1) SE376997B (es)
SU (2) SU446135A4 (es)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4061007A (en) * 1974-07-17 1977-12-06 The Boeing Company Electromagnetic dent remover with electromagnetic localized work coil
US4809411A (en) * 1982-01-15 1989-03-07 Electric Power Research Institute, Inc. Method for improving the magnetic properties of wound core fabricated from amorphous metal
US4833437A (en) * 1986-07-21 1989-05-23 Williamson Windings Inc. Magnetic core inductor
US4908934A (en) * 1987-01-14 1990-03-20 Takeshi Ikeda Process of producing a foil-roll electronic part
US5252941A (en) * 1992-12-11 1993-10-12 At&T Bell Laboratories Spiral, self-terminating coil and method of making the same
US5296830A (en) * 1991-05-27 1994-03-22 Toko Kabushiki Kaisha Choke coil
US20090284338A1 (en) * 2008-05-15 2009-11-19 Eisuke Maruyama Multi-Stage Coil for Transformer, and Coil Winding Method and Apparatus for Manufacturing the Same
US20110205010A1 (en) * 2008-10-01 2011-08-25 3Di Power Limited Inductor For High Frequency Applications

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115331954B (zh) * 2022-10-17 2023-01-24 广州市一变电气设备有限公司 变压器箔式线圈绕制出线方法、绕组及节能环保变压器

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT89042B (de) * 1920-06-12 1922-07-25 Aeg Union Elek Wien Hochkantspulenwicklung für elektrische Maschinen und Apparate.
US2735979A (en) * 1956-02-21 Input
US2879320A (en) * 1957-02-18 1959-03-24 Reynolds Metals Co Insulated strip conductor having end portion folded on controlled radius
US3153216A (en) * 1958-08-11 1964-10-13 Westinghouse Electric Corp Winding arrangement for electrical inductive apparatus
US3464043A (en) * 1967-10-16 1969-08-26 Allis Chalmers Mfg Co Conductor strip transformer winding having improved short circuit strength
US3543205A (en) * 1968-08-05 1970-11-24 Westinghouse Electric Corp Electrical windings

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2735979A (en) * 1956-02-21 Input
AT89042B (de) * 1920-06-12 1922-07-25 Aeg Union Elek Wien Hochkantspulenwicklung für elektrische Maschinen und Apparate.
US2879320A (en) * 1957-02-18 1959-03-24 Reynolds Metals Co Insulated strip conductor having end portion folded on controlled radius
US3153216A (en) * 1958-08-11 1964-10-13 Westinghouse Electric Corp Winding arrangement for electrical inductive apparatus
US3464043A (en) * 1967-10-16 1969-08-26 Allis Chalmers Mfg Co Conductor strip transformer winding having improved short circuit strength
US3543205A (en) * 1968-08-05 1970-11-24 Westinghouse Electric Corp Electrical windings

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4061007A (en) * 1974-07-17 1977-12-06 The Boeing Company Electromagnetic dent remover with electromagnetic localized work coil
US4809411A (en) * 1982-01-15 1989-03-07 Electric Power Research Institute, Inc. Method for improving the magnetic properties of wound core fabricated from amorphous metal
US4833437A (en) * 1986-07-21 1989-05-23 Williamson Windings Inc. Magnetic core inductor
US4908934A (en) * 1987-01-14 1990-03-20 Takeshi Ikeda Process of producing a foil-roll electronic part
US5296830A (en) * 1991-05-27 1994-03-22 Toko Kabushiki Kaisha Choke coil
US5252941A (en) * 1992-12-11 1993-10-12 At&T Bell Laboratories Spiral, self-terminating coil and method of making the same
US20090284338A1 (en) * 2008-05-15 2009-11-19 Eisuke Maruyama Multi-Stage Coil for Transformer, and Coil Winding Method and Apparatus for Manufacturing the Same
US7793880B2 (en) * 2008-05-15 2010-09-14 Hitachi Industrial Equipment Systems Co., Ltd. Multi-stage coil for transformer, and coil winding method and apparatus for manufacturing the same
US20100295647A1 (en) * 2008-05-15 2010-11-25 Eisuke Maruyama Multi-Stage Coil for Transformer, and Coil Winding Method and Apparatus for Manufacturing the Same
US7948347B2 (en) 2008-05-15 2011-05-24 Hitachi Industrial Equipment Systems Co., Multi-stage coil for transformer, and coil winding method and apparatus for manufacturing the same
US20110205010A1 (en) * 2008-10-01 2011-08-25 3Di Power Limited Inductor For High Frequency Applications
US8665048B2 (en) 2008-10-01 2014-03-04 3Di Power Limited Inductor for high frequency applications

Also Published As

Publication number Publication date
GB1356325A (en) 1974-06-12
CA943197A (en) 1974-03-05
DE2144386A1 (de) 1972-03-09
SU446135A4 (ru) 1974-10-05
ES203618Y (es) 1976-05-16
NO130803C (es) 1975-02-12
BE772357A (fr) 1972-01-17
FR2107385A5 (es) 1972-05-05
CH529431A (de) 1972-10-15
AT310895B (de) 1973-10-25
ES203618U (es) 1976-02-01
NO130803B (es) 1974-11-04
SU446135A3 (es) 1974-10-05
NL7112309A (es) 1972-03-10
SE376997B (es) 1975-06-16

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