Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
1999-04-22
2001-05-22
Young, Lee (Department: 3729)
Metal working
Method of mechanical manufacture
Electrical device making
C029S602100, C336S192000
Reexamination Certificate
active
06233814
ABSTRACT:
The invention relates to a magnetic coil and to a method for manufacture thereof.
BACKGROUND OF THE INVENTION
Magnetic coils are known in the art, consisting of
a coil body of wound coil wire, the two ends of which are led outwards,
two contact pins which are each wound round with one end of the coil wire,
two connection tabs which can be coupled to the contact pins and
a plastic sheath.
The electrical connection between the contact pins and the coil wire, which is usually insulated with varnish, is made by a suitable supply of mechanical or electrical energy. In DEA-
43
13 608 for this purpose the contact pin and the coil wire are excited by coupling in of oscillations in the ultrasound range, contacts being produced by the friction between the coil wire which is kept biased and individual regions of the contact pins touching the wound coil wire. The connection tabs are usually welded to the contact pins. The resulting relatively rigid connection leads in the mass production of such magnetic coils to a relatively high failure rate due to breaking of the coil wire which is usually very thin and in some circumstances is only 0.04 mm thick. This breaking occurs due to the unavoidable relative movements of the connection tabs and the coil body during insertion and processing in the plastic sheath mould.
The object of the invention, therefore, is to improve the magnetic coil and the method for manufacture thereof with a view to a lower failure rate and thereby to simplify the manufacture.
SUMMARY OF THE INVENTION
Since the connection tabs are coupled to the contact pins in such a way that on the one hand an electrical connection is ensured and on the other hand a movability of the connection tab relative to the contact pin is ensured in the longitudinal direction thereof, a relatively flexible connection is produced between the contact pin and the connection tabs. This connection absorbs the unavoidable relative movements of the connections tabs with respect to the coil body without breaking of the coil wire on the contact pin.
In a particularly advantageous embodiment the connection between the connection tab and the contact pin not only permits a relative displacement in the longitudinal direction of the contact pin but also transversely with respect to this direction. This results in an additional degree of freedom which ensures an even more flexible connection between the connection tab and the contact pin or coil body.
According to the invention the coil wire, which is usually coated with an insulating layer of varnish, is contacted with the contact pins by dip soldering. For this purpose the region of the contact pins which is wound round with the coil wire is dipped into a solder bath, the temperature of which is so hot that the insulating varnish decomposes and due to the solder an electrical connection is produced between the contact pin and the coil wire.
REFERENCES:
patent: 3138771 (1964-06-01), Goldsmith et al.
patent: 3199178 (1965-08-01), Renskers
patent: 3350670 (1967-10-01), Strauch
patent: 3691656 (1972-09-01), Mochizuki et al.
patent: 3824518 (1974-07-01), Slenker
patent: 3936931 (1976-02-01), Hubbartt
patent: 4354310 (1982-10-01), Hatton
patent: 4774756 (1988-10-01), Dethienne
patent: 4313608 (1993-04-01), None
patent: 61-150313 (1986-07-01), None
patent: 2-21609 (1990-01-01), None
Bast Robert
Grove Horst
Leuschner Werner M.
Rheinlander Heinrich
Rieck Frank
Nass Magnet GmbH
Reising, Ethington, Barnes, Kissele, Learman & McCulloch, P.C.
Tugbang A. Dexter
Young Lee
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