Method of making a coil

• US 6,594,885 B2
• Filed: 12/26/2000
• Issued: 07/22/2003
• Est. Priority Date: 12/26/2000
• Status: Expired due to Fees

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Ilyes, Laszlo S., Mieskoski, James D., Abdel-Tawab, Khaled I., Harsa, Clarence J., Grigor, Gordon A., Nerone, Louis R., Skully, James K.
• Primary Examiner(s): Vo, Peter
• Assistant Examiner(s): TUGBANG, ANTHONY D
• Application Number:
  US09/749,483
• Publication Number:
  US 20020079999A1
• Time in Patent Office: 938 Days
• Field of Search: 296/021, 296/06, 296/05, 294/53, 336/83, 336/205, 336/206, 336/207, 336/208, 264/272.19, 264/272.2, 264/236, 264/347
• US Class Current: 29/606
• CPC Class Codes: H01F 17/045 with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
• CPC Class Codes: H01F 2027/297 with pin-like terminal to be inserted in hole of printed path
• CPC Class Codes: H01F 27/266 Fastening or mounting the core on casing or support on coil H01F27/30
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/125 Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49876 by snap fit

Abstract

A method of assembling a coil includes forming a ferrite core having a top end, a bottom end, an inner opening extending from the top end to the bottom end, a cylindrical outer surface, and a step portion formed near the bottom end, the step portion extending past the outer surface. A first high dielectric material is applied on the outer surface of the ferrite core, then a conductive wire is wound onto the high dielectric material, whereafter a second high dielectric material is applied over the conductive wire.

Claims

1. A method of assembling a coil comprising:

forming a ferrite core having a top end, a bottom end, an inner opening extending from the top end to the bottom end, a cylindrical outer surface, and a step portion formed near the bottom end, the step portion extending past the outer surface;

applying a first high dielectric material onto the outer surface of the ferrite core, the first high dielectric material being in a partially cured state such that the first high dielectric material has a tacky compliant quality;

winding a conductive wire onto the partially cured first high dielectric material, including embedding at least a portion of the conductive wire into the partially cured first high dielectric material, holding the wound conductive wire in a secure position;

applying a second high dielectric material over the conductive wire; and

completing the curing of the first high dielectric material, including forming a hermetic seal around the conductive wire.

2. The method according to claim 1, wherein:

the curing causes the first high dielectric material and the second high dielectric material to form into a single solid mass, wherein the conductive wire is held in a fixed position.

3. The method according to claim 1 further including:

forming a coil holder having, i) a base portion with a base opening formed substantially at a centered area of the coil holder, the base opening being sufficiently sized to provide a passage way to the inner opening of core, and (i) a plurality of snap fit fingers extending from the base portion.

4. The method according to claim 3 further including:

inserting the step portion of the cylindrical ferrite core into the snap fit fingers of the coil holder, wherein the core is locked into engagement with the coil holder.

5. The method according to claim 1 wherein the first high dielectric material is a material different from the second high dielectric material.

6. The method according to claim 1 wherein the steps of applying the first and second high dielectric materials include at least one of coating, spraying, dripping and brushing.

7. A method of assembling a coil comprising:

forming a ferrite core having a top end, a bottom end, an inner opening extending from the top end to the bottom end, a cylindrical outer surface, and a step portion formed near the bottom end, the step portion extending past the outer surface;

applying a first high dielectric material, in a partially cured state having a tacky compliant quality, onto the outer surface of the ferrite core;

winding a conductive wire onto the first high dielectric material, including embedding at least a portion of the conductive wire into the partially cured dielectric material, thereby holding the wound conductive wire in a secure position; and

applying a second high dielectric material over the conductive wire.

8. The method according to claim 7 further including:

curing the first high dielectric material and the second high dielectric material into a single solid mass, wherein the conductive wire is held in a fixed position.

9. The method according to claim 8 wherein

the step of curing includes forming a hermetic seal around the conductive wire.

10. The method according to claim 7 further including:

forming a coil holder having, i) a base portion with a base opening formed substantially at a centered area of the coil holder, the base opening being sufficiently sized to provide a passage way to the inner opening of the core, and (i) a plurality of snap fit fingers extending from the base portion.

11. The method according to claim 10 further including:

inserting the step portion of the cylindrical ferrite core into the snap fit fingers of the coil holder, whereby the core is locked into engagement with the coil holder.

12. The method according to claim 7 wherein the first high dielectric material is a material different from the second high dielectric material.

13. The method according to claim 7 wherein the steps of applying the first and second high dielectric materials include at least one of coating, spraying, dripping and brushing.

14. A method of assembling a coil which includes a core having a top end, a bottom end, an inner opening extending from the top end to the bottom end, and a cylindrical outer surface, the method comprising:

applying a first high dielectric material onto the outer surface of the core;

winding a conductive wire onto the first high dielectric material;

applying a second high dielectric material over the conductive wire;

curing the first high dielectric material and the second high dielectric material into a single solid mass, wherein the conductive wire is held in a fixed position;

inserting the core into a coil holder, the coil holder including a base portion with a base opening, the base opening being sufficiently sized to provide a passage way to the inner opening of the core.

15. The method according to claim 14 wherein the first high dielectric material is a material different from the second high dielectric material.

16. The method according to claim 15 wherein,

the step of applying the first high dielectric material further includes applying the first high dielectric material in a partially cured state such that the first high dielectric material has a tacky compliant quality;

the step of winding the conductive wire onto the partially cured first high dielectric material including embedding at least a portion of the conductive wire into the partially cured high dielectric material, thereby holding the wound conductive wire in a secure position; and

the step of curing includes forming a hermetic seal around the conductive wire.

17. The method according to claim 14 wherein the steps of applying the first and second high dielectric materials include at least one of coating, spraying, dripping and brushing.

18. The method according to claim 14 wherein the step of inserting includes inserting a step portion into snap fit fingers of the coil holder.