US3858312A

US3858312A - Method of winding a coil

Info

Publication number: US3858312A
Application number: US241531A
Authority: US
Inventors: Hashem M Gharaibeh
Original assignee: Thomas International Corp
Current assignee: Thomas International Corp
Priority date: 1972-04-06
Filing date: 1972-04-06
Publication date: 1975-01-07
Anticipated expiration: 1992-01-07
Also published as: JPS504569A; JPS498754A; NL7304730A; GB1422547A; IT982959B; DE2317438A1

Abstract

An improved coil for use such as a degaussing coil in color television receivers. The coil is formed in a novel manner by causing the winding of the coil wires to form the annular bobbin from a strip of flexible channel material. The strip is maintained in an annular configuration by the wire causing its reception in an annular groove defined by a pair of axially spaceable arbor portions. The arbor portions further define means for holding the end of the wire upon initiation of the coilforming operation. The bobbin is preferably formed of a thermoplastic material suitable to be sealed by radio frequency energy permitting the legs of the bobbin channel to be secured together about the coil. The bobbin is discontinuously annular and a portion of the coil may bridge the gap between the opposite ends of the bobbin. Connector portions of the wire are brought out to externally of the bobbin, at least one connector portion being brought out through the gap. Improved means are provided for delivering the radio frequency sealing energy to the bobbin.

Description

United States Patent [191 Gharaibeh [451 Jan. 7, 1975 METHOD OF WINDING A COIL Hashem M. Gharaibeh, Palatine, Ill.

[73] Assignee: Warwick Electronics, Inc., Chicago,

Ill.

[22] Filed: Apr. 6, 1972 [21] Appl. N0.: 241,531

[75] Inventor:

Primary Examiner-Carl E. Hall Attorney, Agent, or FirmWegner, Stellman, McCord, Wiles & Wood [57] ABSTRACT An improved coil for use such as a degaussing coil in color television receivers. The coil is formed in a novel manner by causing the winding of the coil wires to form the annular bobbin from a strip of flexible channel material. The strip is maintained in an annular configuration by the wire causing its reception in an annular groove defined by a pair of axially spaceable arbor portions. The arbor portions further define means for holding the end of the wire upon initiation of the coil-forming operation. The bobbin is preferably formed of a thermoplastic material suitable to be sealed by radio frequency energy permitting the legs of the bobbin channel to be secured together about the coil. The bobbin is discontinuously annular and a portion of the coil may bridge the gap between the opposite ends of the bobbin. Connector portions of the wire are brought out to externally of the bobbin, at least one connector portion being brought out through the gap. Improved means are provided for delivering the radio frequency sealing energy to the bobbin.

13 Claims, 14 Drawing Figures Patented Jan. 7, 1975 3,858,312

4 Sheets-Sheet l DRIVE I WIT? Patented Jan. 7, 1975 4 Sheets-Sheet 2 AAA/Q Patented Jan. 7, 1975 3,353,312

4 Sheets-Sheet 4 METHOD OF WINDING A COIL BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to coil manufacture and in particular to manufacture of relatively large diameter coils such as for use as degaussing coils for color television receivers.

2. Description of the Prior Art One method of forming an electrical coil as shown in U.S. Letters Pat. to Freeman, et al., 3,443,136 is to provide a pair of oppositely spaced insulating liners in a channel defined outwardly by a removable plate. The liners are retained in the channels by holding one side as by a clip and blowing air against the other side. The liners are laid in the channel prior to the winding of the coil therein.

In the U.S. Letters Pat. to Gartner 2,399,631, a coil is wound on an adhesive coated sheath which is closed on itself upon completion of the winding of the coil. The sheath is formed by impaling the opposite ends thereof on a plurality of pins whereby the sheath ends overlap to form a continuous annular strip.

SUMMARY OF THE INVENTION The present invention comprehends an improved coil manufacture wherein a channel element formed of a suitable material sealable by heat is formed into an annular configuration by the action of the placement of the wire in the channel in association with an annular arbor. One end of the strip is held to the arbor adjacent the end of a wire supply and the arbor is then rotated to cause a laying down of the wire in the radially outwardly opening channel and concurrently urge the channel into an annular groove in the arbor. Upon completion of one turn, the wire holds the channel in the arbor groove in the desired annular bobbin configuration, permitting further turns of the arbor to be effected suitably for laying down additional turns of the coil. The channel and arbor groove may have engagement of preselected shoulders for maintaining the radially outwardly opening arrangement of the channel in the groove while yet permitting the internal cross section of the channel to be round and thereby facilitate forming of the coil therein. The legs of the channel may be maintained spaced apart adjacent the delivery of the wire thereinto to assure proper feed of the wire in the coil-forming operation.

After a small number of turns have been applied to assure proper retention of the channel in the annular bobbin configuration in the arbor groove, the speed of rotation of the arbor may be increased so as to increase the rate of coil formation. The final winding of the coil may be preselected so as to terminate short of an integral number of turns as desired. Upon completion of the winding of the desired coil, sealing elements may be brought into engagement with the channel legs to urge them together and concurrently effect sealing thereof by provision of heat energy thereto. The invention comprehends an improved sealing assembly construction for providing radio frequency energy uniformly along the length of the legs to effect the seal. As indicated above, one of the electrical connections may be brought out spaced from the gap between the opposite ends of the channel and, thus, an opening in the sealed leg structure may be provided at that point.

The end of the wire may be held at the start of the coil winding operation by the use of an axially split arbor having frictional portions adapted to clamp the wire end therebetween when the split portions are urged together at the start of the coil-forming operation. The split arbor portions may jointly define the desired annular groove in which the channel is received to form the bobbin and, thus, upon separation of the arbor portions at completion of the coil assembly operation, the annular coil assembly may be removed radially through the gap between the axially spaced arbor portions, as the held wire end is released concurrently. The means for delivering the wire into the channel as it is being rotated on the arbor may comprise a delivery head having a depending guide adapted to fit between the channel legs and maintain the channel legs spaced apart to assure proper delivery of the wire into the channel. Upon completion of the coil-forming step, the delivery head is automatically retracted to permit the desired sealing together of the leg portions.

To provide the desired uniform radio frequency energy to the channel legs, a pair of sealing assemblies is provided wherein the radio frequency energy is delivered to segmentally spaced annular portions thereof by means of a feeder bus structure conducting the radio frequency energy to the separate plate segments. The bus includes a first arcuate distributor portion connected to less than all of the segments and a second arcuate distributor portion connected to the remaining segments and to at least one of the segments to which the first distributor is connected. The two distributors may be on opposite faces of the sealing assembly and a radial portion may extend from one of the distributors for connection thereof to the power supply or ground as desired.

BRIEF DESCRIPTION OF THE DRAWING Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein:

FIG. 1 is a fragmentary front elevation of a coilforming apparatus embodying the invention;

FIG. 2 is a fragmentary front elevation thereof as upon initiation of the sealing operation;

FIG. 3 is an enlarged cross section of the bobbin at a position forwardly of the wire feed guide upon winding of an initial number of turns thereon in the apparatus;

FIG. 4 is an enlarged cross section similar to that of FIG. 3 but with the bobbin sealed closed about the coil as during the sealing step;

FIG. 5 is a fragmentary perspective view of the apparatus illustrating the feed of the wire and the bobbin strip into association with the apparatus upon initiation of the coil-forming operation;

FIG. 6 is a fragmentary perspective view illustrating the start of the coil-forming operation;

FIG. 7 is a fragmentary enlarged vertical section taken substantially along the line 7-7 of FIG. 6;

FIG. 8 is a side elevation of the heat sealing means;

FIG. 9 is a fragmentary vertical section illustrating further the securing of the wire and strip ends at the initiation of the coil-forming operation;

FIG. 10 is a fragmentary vertical section illustrating the arrangement of the bobbin and wire upon completion of the winding of the first turn;

FIG. 11 is a side elevation of the completed coil;

FIG. 12 is an end elevation thereof;

FIG. 13 is a fragmentary front elevation of an alternate form of the apparatus; and

FIG. 14 is a fragmentary enlarged cross section taken along lines 1414 of FIG. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENT In the exemplary embodiment of the invention as disclosed in the drawing, an apparatus generally designated is shown for winding a coil in a novel improved manner. In illustrating the invention, it will be considered that the coil is a relatively large diameter coil such a degaussing coil for use in a color television receiver, it being understood that other suitable coils may be formed correspondingly.

The apparatus 10 includes a wire feed head 11 which is selectively moved from a retracted position to a feeding position as shown in FIG. 1 for delivering a wire 12 to between a pair of axially

split arbor portions

13 and 14. The righthand arbor portion 13 is axially fixed while the lefthand arbor portion 14 is axially movable to and from the arbor portion 13. Arbor portion 13 is regidly affixed to a shaft 15, while arbor portion 14 is rotatably mounted at 16 to a shaft 17. Any suitable means, such as a hydraulic cylinder (not shown), may be used to effect axial movement of shaft 17 and, hence, determine the position of arbor portion 14.

Thus, as shown in FIG. 2, when arbor portion 14 is brought into facial engagement with arbor portion 13, the arbor portions effectively define an arbor 18 having a radially outwardly opening circumferential groove 19. The

arbor portions

13 and 14 are provided with frictional surfaces 20 which are fixedly clamp the end 21 of the wire 12 when the arbor portions are brought together. A clip 22 is provided on arbor portion 13, as shown in FIG. 5, for receiving the end ofa channel strip 23. Thus, as shown in FIG. 6, when the

arbor portions

13 and 14 are brought together with the wire end 21 held therebetween, the leading strip end 24 is inserted into the groove 19 to engage the clip 22 so that the end 24 is disposed within the groove 19 closely adjacent the wire end 21.

Strip 23 effectively comprises a channel element formed of a flexible electrically insulating material such as a thermoplastic. The length of the strip is preselected to be slightly less than the annular length of the groove 19 so that the distal end 25 of the strip is spaced slightly from the first end 24, as shown in FIG. 10, when the strip is received in the groove 19in a corresponding annular configuration. The strip is caused to be received in the groove 19 by the wire 12 as a result of the laying of the wire into the channel strip. More specifically, upon insertion of the strip end 24 into the clip 22, as shown in FIG. 9, the arbor 18 is rotated in a counterclockwise direction as seen therein whereby the wire enters into the channel strip 23 and urges the channel strip downwardly into the groove 19. Upon one complete turn of the arbor, as shown in FIG. 10, the strip 23 effectively defines a discontinuously annular bobbin having a gap 26 between ends 24 and 25. Continued rotation of the arbor in the counterclockwise direction effects the winding of additional turns of wire in the channel bobbin as illustrated in FIG. 3. To facilitate placement of the wire in the channel, a depending guide 27 is provided on head 11 maintaining the

legs

28 and 29 of the channel strip 23 spaced apart adjacent the clip 22. As shown in FIG. 3, strip 23 defines an externally squared cross section including corner shoulder portions 30 which cooperate with the squared groove corner shoulder portions 30a to prevent twisting of the channel strip in the groove and maintain the channel opening accurately outwardly during the coil winding operation. The channel strip 23 further defines a circular cross section internal configuration which causes the completed coil to have a circular cross section as shown in FIG. 4.

As shown in FIG. 3, the

channel legs

28 and 29 terminate in flat

outer portions

31 and 32. The

channel leg portions

31 and 32 extend outwardly from the groove 19 so that upon completion of the winding of the coil 33 in the arbor channel, the

leg portions

31 and 32 may be sealingly joined by the urging together thereof effected by a pair of opposed

annular flanges

34 and 35 associated with a pair of axially spaced sealing assemblies 36 and 37, respectively. As shown in FIG. 4, the flanges force the

opposed leg portions

31 and 32 into facial engagement to effectively close the channel 23 about the wound coil. The leg portions may be autogenously bonded together as by use of radio frequency energy transmitted through the

flanges

34 and 35.

The sealing assemblies 36 and 37 are similar in construction. As shown with reference to FIGS. 8 and 14, the sealing assemblies each comprise a segmentally annular construction formed of a plurality of sealing elements 38 spaced annularly apart and secured to a conductive back-up plate 39 which is correspondingly segmented. The segmented back-up plate 39 is secured to a non-conductive plate which is not segmented. The gap 40 between the segmented portions of the sealing elements and between the corresponding portions of the back-up plate is preferably relatively small, illustratively such as one-sixteenths inch.

The

members

38, 39, and 60 of both sealing assemblies 36 and 37 are of annular construction so as to allow the appropriate one of the

arbor shafts

15 and 17 to pass freely therethrough. Radio frequency energy is transmitted to the sealing elements through a bus structure generally designated 41, which includes a first arcuate distributor 42 overlying a number of the segmented sealing elements. The distributor 42 is positioned behind the conductive plate 39 and adjacent the nonconductive plate 60 such that the segmented sections of plate 39 are not contacted. In the illustrated embodiment, the distributor 42 is shown overlying approximately one-half of the sealing elements and extending arcuately approximately l. A second arcuate distributor comprising a pair of

elements

43 and 44 is provided overlying the opposite surface of plate 39, the elements extending approximately 1209 each and being spaced apart approximately 60 at their opposite ends symmetrically to the centerline of the first distributor 42, as shown in FIG. 8. The

distributor elements

43 and 44 are connected at points intermediate their length to distributor 42 by conductive connecting means generally designated 45. In the embodiment shown, each of the connecting means 45 includes boss portions 47 surrounding an aperture 46 in plate 39 and a screw 48 which passes through distributor element 43 and threads into distributor element 42. Thus,

distributor elements

42 and 43 are in electrical contact with each other and with the plate 39 at the connection means 45.

Distributor elements

43 and 44 are connected to the various segments of plate 39 by conductive connecting means generally designated 45. The construction of connecting means 45 may be similar to that of connecting means 45 but for the fact that distributor element 42 has no connection with the plate 39 or the

distributor elements

43 and 44 at these points. Thus, distributor element 42 supplies the radio frequency energy to the intermediate portions of

distributor elements

43 and 44 which, in turn, distribute the energy to the various segments of the segmented plate 39 and hence, to the corresponding sealing elements 38. Screws such as that shown at 52 or other suitable fastening means may be used to secure the segments of plate 39 to the annular insulating plate 60. Similarly, the insulating plate 60 is secured to plate 54 by means of screws such as illustrated at 63.

A conducting means 49 is provided extending radially outwardly from distributor 42 for conducting radio frequency energy from a suitable source (not shown) to one of the sealing plates and for use in grounding the opposite sealing plate.

Axial movement of the sealing assemblies 36 and 37 and the resulting movement of

flanges

34 and 35 into respective engagement with the

leg portions

31 and 32 of the channel strip 23 is effected by means of

hydraulic cylinders

50 and 51, respectively. In the embodiment of the apparatus shown in FIGS. 1 and 2, the

hydraulic cylinders

50 and 51 are located co-axially with respect to the winding arbor shafts and 17. The movable members or

pistons

52 and 53 associated with the hydraulic cylinders are hollow, surrounding their respective arbor shafts so as to permit relative axial movement therebetween.

Pistons

52 and 53 are secured to

plates

54 and 55, respectively, which carry the sealing assemblies 36 and 37. A pair of parallel guide bars 56 and 57 are secured to a pair of fixed

brackets

58 and 59 as shown, and passed through diametrically opposed apertures in

plates

54 and 55. The

brackets

58 and 59 are rigidly secured to the base 61 for the apparatus. In this manner, the movement of the sealing plates is carefully controlled to ensure an accurate meeting of the sealing elements during each sealing operation.

Alternatively, as shown in FIG. 13, in a second embodiment of the apparatus generally designated 110, the sealing

members

136 and 137 may be rigidly secured to a pair of

brackets

158 and 159, respectively, which are slidably carried on a base 161.

Hydraulic cylinders

150 and 151 effect axial movement of the

brackets

158 and 159 and are affixed to the base 161 by means of appropriate supports such as illustrated at 190 and 191. The

supports

190 and 191 also serve as mounting means for the

shafts

115 and 117 associated with the winding arbor 118. A hydraulic cylinder 192 for effecting axial movement of arbor shaft 117 may also be mounted to support 191. Operation of

hydraulic cylinders

150 and 151

causes brackets

158 and 159 to move along a path determined by

guide members

193 and 194, which are affixed to the base 161 and configured so as to permit only movement along the axis of the sealing

members

136 and 137.

As shown in FIG. 11, the leg portions of the bobbin channel are joined throughout the length of the bobbin except at spaced portions 64 aligned with the gaps 40 of the sealing plate where the bond will be of lesser strength.

Flanges

34 and 35 may be provided with a notch 65 to provide a gap 66 in the closed bobbin spaced from the gap 26 where the last turn of the coil is not a complete turn to permit bringing the finish end 67 of the wire 12 outwardly through the bobbin.

Upon completion of the joining of the

leg portions

31 and 32 of the bobbin to complete the enclosing of the coil 33, the wire feed head 11 retracts upwardly, the wire 12 is cut, and arbor portion 14 is retracted along its axis whereupon the bobbin may be disengaged from clip 22 and brought forwardly through the space between the arbor portions as the wire end 21 is also automatically released by the spacing of the arbor portions.

The rotation of the complete arbor 18 may be effected by rotatably driving the shaft 15 to which arbor portion 13 is affixed, thereby causing arbor portion 14 to rotate due to frictional engagement between the arbor portions. A suitable motor drive may be applied as shown at 68 and may be controlled by suitable automatic control equipment (not shown) to effect the desired operation of apparatus 10 to effect the formation of the coil as discussed above. Illustratively, the apparatus may be operated to effect rotation of the arbor at a relatively slow rate during the laying down of the first turn or several turns and effect a high speed winding of the remaining turns once the bobbin is firmly set in place in the arbor groove 19 and held therein by the wire. Where the last turn of the coil is less than a full turn, the gap 26 will be spaced downwardly from the uppermost position. However, the sealing plate gap 65 is fixed at the uppermost position in alignment with the end 67 of the wire and, thus, the opening 66 is automatically positioned to accommodate the outward extension 67 of the wire. Thus, for example, a coil having a large number of full turns and a final fractional turn may be accurately and quickly formed. A suitable cutter (not shown) may be provided for cutting the wire upon completion of the sealing closure of the bobbin leg portions.

The use ofthe split arbor permits facilitated initiation of the coil winding operation while permitting ready removal of the completed coil. The depending wire end 21 need not extend directly vertically downwardly as long as it extends between the frictional surfaces 20. Thus, guiding means are obviated while yet the wire end is positively held at the initiation of the coil winding operation. The use of the wire itself to form the annular bobbin from an effectively rectilinear channel strip permits high speed facilitated forming of the coil. The self-guiding action of

portions

31 and 32 of the channel strip and the guide 27 combine to ensure an accurate laying down of the wire turns in the annularly arranged bobbin upon completion of the first turn of wire thereabout. The axial movability of the arbor portions and sealing plates facilitates the coil-forming operation while yet assuring positive accurate forming of the coil in the bobbin strip 23. It has been found that the use of apparatus 10 permits the forming of such coils with an operator having no special skills and permitting the operation by such an operator of a plurality of such machines concurrently as the need for manipulation of the apparatus and bobbin strip occurs only at the beginning and end of the coil winding operation.

The resultant coil is relatively flexible, permitting the accommodation thereof to the cathode ray tube for degaussing operation. If desired, the gap 26 between the end portions of the bobbin may be sealed by a suitable closure strip (not shown) wrapped thereabout.

The segmented construction of the sealing members and the configuration of the RF energy distribution members associated therewith combine to permit uniform high quality sealing of the bobbin leg portions on each coil produced. The construction of the sealing members also permits facilitated changeover for accomodating bobbins of various diameters, in that the segmented sealing elements 38 may be removed from the segmented back-up plate 39 and replaced with an alternate set of such elements of a different size without disturbing the RF energy distribution system.

As will be obvious to those skilled in the art, by use of the axially split arbor, the channel strip may be provided originally in a complete annular form which is captured in the arbor groove when the arbor portions are brought together. Where such a continuously annular arbor strip is used, the clip 22 may be omitted and the wire end 21 may be brought down through a suitable opening in the bight of the channel to be received between the frictional wire engaging surfaces 20. In this case, the wire does not effect the forming of the annular configuration of the strip, but in all other respects, the forming of the coil is similar to the forming of coil assembly 52 discussed above.

The foregoing disclosure of specific embodiments is illustrative of the broad inventive concepts comprehended by the invention.

Having thus described the invention, I claim:

1. A method of forming a coil assembly, comprising the steps of:

capturing a wire between two members which cooperate to form an annular winding arbor;

disposing a first end of a flexible, channel-shaped strip of insulating material on said arbor adjacent the captured wire;

applying a first turn of wire about said strip beginning at said first end and progressing therealong so as to retain the strip against said arbor to define a bobbin of annular configuration; and

applying a preselected number of additional turns of said wire about said annular bobbin to form an annular coil coaxially carried by said bobbin. 2. The method of forming a coil assembly of claim 1 further including the steps of:

sealing said insulating strip about the radially outer periphery of said coil, and

subsequently separating said arbor members to release the captured wire and the completed coil assembly.

3. A method of forming a coil assembly, comprising the steps of: holding one end of a flexible channel element; causing the channel element to extend from said held end in an annular configuration about an arbor with the channel element opening radially outwardly and with the oposite end of the channel element spaced adjacent said one end; retaining one end of a wire circumferentially adjacent said one end of the channel element; and winding the wire into said annular channel element to form a wire coil in said channel element with said one end of the wire extending through the space between said ends of the channel element.

4. The method of forming a coil assembly of claim 3 wherein said one end of the flexible channel element is secured to a winding arbor having an annular outer surface and said channel element is progressively moved against said arbor from said held end by the wire as it is wound into said channel to form said annular c0nfiguratton.

5. The method of forming a coil assembly of claim 4 further including the steps of providing cooperating shoulder means on said channel element and arbor and causing said shoulder means to engage during the winding of the wire coil in the channel to maintain said channel opening accurately radially outwardly.

6. The method of forming a coil assembly of claim 3 further including the step of autogenously bonding the channel element legs radially outwardly of the wire coil together to enclose the coil in said channel element.

7. A method of forming a coil assembly, comprising the steps of: providing a supply of coil wire; providing a winding arbor; holding one end of the wire adjacent said arbor; placing one end of a flexible channel element adjacent said held end of the wire and said arbor with the channel element extending outwardly away from said arbor; causing the wire to be laid in said channel element progressively from said end while concurrently causing the wire to urge the channel element into an annular configuration about said arbor; and wrapping additional turns of said wire in said annular channel element to form a coil and maintain said channel element in said annular configuration.

8. The method of forming a coil assembly of claim 7 wherein said arbor defines an annular groove and the channel element is reformed by the wire into the annular groove and is maintained therein by the wire during the winding of the coil.

9. The method of forming a coil assembly of claim 8 wherein said winding arbor comprises a pair of separable members, said separable members being caused to separate radially inwardly of said annular groove to free said coil assembly therefrom upon completion of the coil winding.

10. The method of forming a coil assembly of claim 7 wherein said channel element is preselected to have a length shorter than the annular length of the coil assembly whereby said channel element is discontinuously annular in said coil assembly.

11. The method of forming a coil assembly of claim 7 wherein said one wire end is releasably frictionally clamped to said arbor.

12. The method of forming a coil assembly of claim 7 wherein said held end of the wire and said channel element are caused to move in an annular path to draw the wire into the channel from said supply.

13. The method of forming a coil assembly of claim 7 wherein means are provided for maintaining the legs of the channel element spaced apart adjacent the delivery of wire from said supply to the channel.

Claims

1. A method of forming a coil assembly, comprising the steps of: capturing a wire between two members which cooperate to form an annular winding arbor; disposing a first end of a flexible, channel-shaped strip of insulating material on said arbor adjacent the captured wire; applying a first turn of wire about said strip beginning at said first end and progressing therealong so as to retain the strip against said arbor to define a bobbin of annular configuration; and applying a preselected number of additional turns of said wire about said annular bobbin to form an annular coil coaxially carried by said bobbin.

2. The method of forming a coil assembly of claim 1 further including the steps of: sealing said insulating strip about the radially outer periphery of said coil, and subsequently separating said arbor members to release the captured wire and the completed coil assembly.

4. The method of forming a coil assembly of claim 3 wherein said one end of the flexible channel element is secured to a winding arbor having an annular outer surface and said channel element is progressively moved against said arbor from said held end by the wire as it is wound into said channel to form said annular configuration.