Method of winding electrical and electronic components

• US 6,948,676 B1
• Filed: 07/06/2004
• Issued: 09/27/2005
• Est. Priority Date: 07/06/2004
• Status: Expired due to Fees

• Current Assignee: John K. Tremblay
• Original Assignee: John K. Tremblay
• Inventors: Tremblay, John K.
• Primary Examiner(s): Matecki, Kathy
• Assistant Examiner(s): Langdon, Evan H
• Application Number:
  US10/884,275
• Time in Patent Office: 448 Days
• Field of Search: 242/434.7, 242/434.8, 242/434.9, 242/434.5, 296/05, 297/37, 298/20
• US Class Current: 242/434.7
• CPC Class Codes: H01F 41/08 Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

A method of forming a toroid coil on a toroidal body. Ferrous material is attached to conductive wire. Magnetic force is then used to manipulate the conductive wire about the toroid core.

Claims

1. A method of winding toroid cores comprising the steps of:

attaching a block of ferrous material which has magnetic properties to a first end of a conductive wire;

providing a notched glass plate, said glass plate having an upper surface and a bottom surface, said glass plate laying in a horizontal plane;

placing a toroid having a central opening in a holding assembly adjacent to said notched glass plate, the toroid being positioned within the glass plate notch and positioned in a vertical plane, said toroid having a circumferential plane transverse to the plane of the glass plate;

providing a rotating element positioned beneath and parallel to the glass plate bottom surface, said element being rotated by a drive bar, said element being rotated in a plane parallel to the plane of the glass bottom surface, said rotating element having an upper surface with two opposite ends, one end having a magnet fixedly attached thereto;

attaching a second end of said conductive wire to the toroid;

providing a feeder assembly adapted to placing the block initially through the toroid central opening onto to the glass plate upper surface;

rotating said rotating element wherein said magnet magnetically engages said block, said block moving with said magnet and swinging in a general circular motion out toward the glass plate perimeter, said block passing through said toroid central opening;

continuing rotation of said rotating element until all of said wire is wound about the toroid.

2. A method as recited in claim 1, further comprising the steps of:

cutting the block into a lead slug and a trailing slug wherein said lead slug is attached to said conductive wire first end and said trailing slug is attached to a conductive wire second end.

3. A method as recited in claim 2, wherein the step of attaching a block of ferrous material to a first end of a conductive wire comprises the steps of:

making a concentrated slurry of sponge iron powder in an adhesive;

pouring the slurry into a mold;

passing said conductive wire first end into the mold on center along a mold'"'"'s longitudinal axis;

applying a magnetic field with a desired magnetic domain and polarization;

removing a resulting ferrous block with conductive wire end attached from the mold.

4. A method as recited in claim 3, further comprising the step of:

providing a magnetically-inert guide on said glass plate upper surface on both sides of the toroid.

5. A method as recited in claim 4, further comprising the step of:

providing a counter weight on said rotating element upper surface on a second opposite end.

6. A method as recited in claim 5, further comprising the step of:

providing means for moving the magnet and counter weight closer to each other thereby forming a radially declining circle.

7. A method as recited in claim 6, wherein the step of providing a feeder assembly comprises the steps of:

providing an elongated tube into which a wire with lead slug and trailing slug is inserted;

providing pneumatic means for accelerating said wire lead slug out through a tube exit through the toroid central opening;

snagging said trailing slug with a trap adjacent to said tube exit;

providing a plurality of sensors along side said tube, said sensors sensing the positions of the lead and trailing slugs within the tube.

8. A method as recited in claim 7, wherein the step of providing a holding assembly comprises the steps of:

providing two belt subassemblies positioned one over the other in a spaced relationship, said belt subassemblies adapted to hold the toroid between them and adapted to turning thereby advancing the toroid.

9. A method as recited in claim 8, further comprising the step of:

applying a thin film of pressure sensitive adhesive to the toroid prior to rotating the rotating element.