Multi-Turn Electrical Coil and Fabricating Device and Associated Methods

A coil former comprising:

• a first plate having a first side wall;
• a second plate having a second side wall;
• and
• a block positioned within peripheries of and between the first and second plates for fixing a space between opposing first and second side walls, wherein a peripheral wall surface of the block extending from the opposing side walls is tapered inwardly from the first side wall toward the opposing second wall, and wherein the opposing plates and block are fixed secured to each other.

A method of forming a coil using a coil former having a first side wall in spaced relation to an opposing second side wall, wherein a cavity is formed therebetween and dimensioned for receiving multiple turns of wire for forming the coil therein, and a block fixed between the opposing first and second side walls, wherein a peripheral wall surface of the block is tapered from one end to an opposing end thereof and from the first wall surface inwardly toward the opposing second wall, the method comprising:

• providing a single strand of wire;
• folding the strand of wire around one tapered end portion of the block while leaving first and second ends of the strand of wire extending outwardly from the cavity;
• placing tension on the strand of wire and biasing the strand of wire against the one end of the tapered block;
• winding the first end of the strand of wire in one of a counterclockwise or clockwise selected movement toward the block opposing end to place the first end of the strand of wire against an inner most tapered portion of the block so as to form turn one of the coil;
• winding the second end of the strand of wire toward and around the block opposing end in an opposite direction than the first end and making a full revolution stopping proximate the opposing end of the block, thus establishing turn two of the coil and a first layer for the coil;
• winding of the first end of the strand of wire in the selected movement through one revolution around the block, wherein the first end of wire crosses over the second end of the strand of wire proximate the opposing end of the block;
• and
• continuing to wind the first and second ends of the strand of wire in alternating fashion through their respective selected movements until a preselected number of turns is reached.

A method of forming a coil using a coil former having a first side wall in spaced relation to an opposing second side wall and a block fixed therebetween, wherein a periphery of the block is tapered inwardly from the first side wall toward the opposing second wall, the method comprising:

• providing a single strand of wire;
• folding the strand of wire around the first one of the block while leaving first and second ends of the strand of wire extending outwardly therefrom;
• placing tension on the strand of wire and biasing the strand of wire against the tapered block;
• winding the first end of the strand of wire in one of a counterclockwise or clockwise selected movement toward the second end of the block to place the first end of the strand of wire against an inner most tapered portion of the block;
• winding the second end of the strand of wire toward and around the second end of the block in an opposite direction than the first end and making a full revolution stopping proximate the opposing end of the block, thus establishing a first layer for the coil;
• winding of the first end of the strand of wire in the selected movement through one revolution around the block, wherein the first end of wire crosses over the second end of the strand of wire proximate the second end of the block;
• and
• continuing to wind the first and second ends of the strand of wire in alternating fashion through their respective selected movements until a preselected number of turns is reached.