Method of connecting wire leads to miniature coil assemblies

Abstract

The invention relates to a method of fastening electrical wire leads to each end of a ferromagnetic sleeve or core form in a manner whereby significantly greater bonding strength is provided between the leads and the core as compared to prior art methods. The core and wire leads are placed in a molding cavity into which molding material is injected so as to affirmatively fill the clearance between the lead ends and the core thereby resulting in a highly effective cementing of one to the other. The core body is hollow so that the molding material passes through each end to completely fill the central portion of the core. In this manner the central bore through the core body provides effective gating to the injected molding material. The ferromagnetic coil article so formed includes a molded flange on each of its ends which extend radially outward from the outer surface of the core body associated therewith. The flanges serve to protect a coil winding disposed therebetween about the core from a variety of conditions.

Dependencies are inferred from the claim text.