Continuous method of manufacturing wire wound inductors and wire wound inductors thereby
First Claim
1. A method of manufacturing inductors comprising:
- (a) extruding a length of core material;
(b) subsequently forming and crimping wire staple terminals around the core material from a bendable wire material; and
(c) wrapping wire windings around the core material between the wire staple terminals and connecting the wire windings to the wire staple terminals.
3 Assignments
0 Petitions
Accused Products
Abstract
A wire-wound inductor includes a dielectric core, terminals including wire staples that are crimped around the core, and a wire winding disposed about the perimeter of the core and connected to the terminals. A coating such as an adhesive coating is disposed over the wire winding and between the terminals. The process for manufacturing the inductors in a continuous process. Beginning with a spooled material, which may be extruded, inductors are formed on a core material sequentially. The inductors are not physically separated until the final stages of manufacturing, which is in contrast to the prior art method in which each inductor is individually constructed on an individual core that has been manufactured with tight tolerances and wound individually. By virtue of the characteristics of the inductor components, extremely tight tolerances (typically about 0.0005") can be obtained, resulting in highly controlled inductance values.
36 Citations
28 Claims
-
1. A method of manufacturing inductors comprising:
-
(a) extruding a length of core material; (b) subsequently forming and crimping wire staple terminals around the core material from a bendable wire material; and (c) wrapping wire windings around the core material between the wire staple terminals and connecting the wire windings to the wire staple terminals. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
-
-
16. A method of manufacturing inductors comprising:
-
(a) extruding a length of core material sufficient for a plurality of inductors; (b) subsequently forming and crimping wire staple terminals from a bendable wire material around the core material along the length of core material in locations corresponding to the plurality of inductors; and (c) wrapping wire windings around the core material between the wire staple terminals and connecting ends of the wire windings to pairs of the wire staple terminals corresponding to each of the plurality of inductors, respectively. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
-
Specification