Method of making an electromagnetic transducer

A method of producing an armature for an electromagnetic transducer, said method comprising:

• (a) preparing a plurality of preformed discrete elongated high-permeability flux carrying members;
• (b) preparing n wire bundles, where in is at least two for a two-phase winding and at least three for a three phase winding, each said wire bundle having a predetermined length, each one of said wire bundles being formed of a plurality of substantially parallel wires;
• (c) winding said n wire bundles to provide a distributed winding configuration having a plurality of elongated open spaces;
• (d) inserting said plurality of flux carrying members into said plurality of open spaces in a one-to-one relationship such that one flux carrying member is in one open space to provide a winding/flux carrying member assembly;
• and
• (e) providing a bonding material around said winding/flux carrying member so as to provide a rigid structure.

A method of producing an armature for an electromagnetic transducer, said method comprising:

• (a) preparing a plurality of preformed, discrete elongated high-permeability flux carrying members by producing a multiplicity of insulated fine iron powder particles and pressing a predetermined amount of said insulated fine iron particles together to yield said plurality of said flux carrying members;
• (b) preparing n wire bundles each having a predetermined length, each one of said wire bundles being formed of a plurality of parallel wires;
• (c) providing a winding mandrel comprising a cylinder having a plurality of slots on its surface oriented parallel to a longitudinal axis of said cylinder, said slots being uniformly spaced around a circumference of said cylinder;
• (d) providing a plurality of removable blades each having one end positioned in one of said plurality of slots and another end oriented to project from said surface of said cylinder, said blades having a thickness and width generally as said flux carrying members, adjacent ones of said blades forming a space therebetween;
• (e) inserting a first bundle of said n wire bundles into a first space between adjacent ones of said blades such that a linear center point of said first bundle is positioned generally at a midpoint of said first space;
• (f) inserting second through nth ones of said n wire bundles successively into said second through nth adjacent spaces between adjacent ones of said blades in a first direction around said circumference of said cylinder such that said second through nth bundles have respective linear center points positioned respectively generally at midpoints of said spaces;
• (g) moving two ends of said first bundle in said first direction under said second through nth bundles toward a next adjacent space n+1 adjacent to said second through nth adjacent spaces, inserting said two ends into said next adjacent space n+1 and tensioning said two ends to form a loop between said first space and said n+1 space;
• (h) repeating step (g) for each successive second through nth bundle by moving two ends of said second through nth bundles successively in said first direction toward next adjacent spaces, inserting said two ends in said respective next adjacent spaces and tensioning said two ends to form loops;
• (i) repeating steps (g) and (h) until said first through nth bundles have been inserted into final ones of said spaces around said circumference of said cylinder;
• (j) terminating the ends of said first through nth bundles after said first through nth bundles have been inserted into said final ones of said spaces;
• (k) removing said blades from said slots in said cylinder;
• (l) separating said first through nth bundles from said cylinder, whereby the wire bundles braided as in steps (c)-(k) form a distributed winding configuration being in the shape of a substantially cylindrical shell including a plurality of spaced apart elongated winding segments wherein adjacent ones of said winding segments are connected to one another, said winding segments having a plurality of elongated open spaces interdigitated therebetween;
• (m) thereafter inserting said plurality of flux carrying members into said plurality of open spaces in a relationship such that at least one flux carrying member is in one said open space to provide a winding/flux carrying member assembly, said plurality of flux carrying members being formed in a substantially elongated shape and said plurality of open spaces being formed in a substantially elongated shape;
• and
• (n) providing a non-electrically conductive bonding material around said winding/flux carrying member assembly to provide a substantially rigid structure.

A method of producing an armature for an electromagnetic transducer, said method comprising:

• (a) preparing a plurality of preformed discrete elongated high-permeability flux carrying members;
• (b) preparing n wire bundles, where in is at least two for a two-phase winding and at least three for a three phase winding, each said wire bundle having a predetermined length, each one of said wire bundles being formed of a plurality of substantially parallel wires;
• (c) winding said n wire bundles to provide a distributed winding configuration having a plurality of elongated open spaces;
• and
• (d) inserting said plurality of flux carrying members into said plurality of open spaces in a relationship such that at least one flux carrying member is in one open space to provide a winding/flux carrying member assembly.

A method of producing an armature for an electromagnetic transducer, said method comprising:

• (a) preparing a plurality of preformed, discrete elongated high-permeability flux carrying members by producing a multiplicity of insulated fine iron powder particles and pressing a predetermined amount of said insulated fine iron particles together to yield said plurality of said flux carrying members;
• (b) preparing n (n>0) wire bundles each having a predetermined length, each one of said wire bundles being formed of a plurality of parallel wires;
• (c) providing a winding mandrel comprising a cylinder having a plurality of slots on its surface oriented parallel to a longitudinal axis of said cylinder, said slots being uniformly spaced around a circumference of said cylinder;
• (d) providing a plurality of removable blades each having one end positioned in one of said plurality of slots and another end oriented to project from said surface of said cylinder, said blades having a thickness and width generally as said flux carrying members, adjacent ones of said blades forming a space therebetween;
• (e) inserting a first bundle of said n wire bundles into a first space between adjacent ones of said blades such that a linear center point of said first bundle is generally positioned at a midpoint of said first space;
• (f) inserting second through nth ones of said n wire bundles successively into said second through nth adjacent spaces between adjacent ones of said blades in a first direction around said circumference of said cylinder such that said second through nth bundles have respective linear center points positioned respectively generally at midpoints of said spaces;
• (g) moving two ends of said first bundle in said first direction under said second through nth bundles toward a next adjacent space n+1 adjacent to said second through nth adjacent spaces, inserting said two ends into said next adjacent space n+1 and tensioning said two ends to form a loop between said first space and said n+1 space;
• (h) repeating step (g) for each successive second through nth bundle by moving two ends of said second through nth bundles successively in said first direction toward next adjacent spaces, inserting said two ends in said respective next adjacent spaces and tensioning said two ends to form loops;
• (i) repeating steps (g) and (h) until said first through nth bundles have been inserted into final ones of said spaces around said circumference of said cylinder;
• (j) terminating the ends of said first through nth bundles after said first through nth bundles have been inserted into said final ones of said spaces;
• (k) forming said first through nth bundles, whereby the wire bundles braided as in steps (c)-(i) form a distributed winding configuration being in the shape of a substantially cylindrical shell including a plurality of space apart elongated winding segments wherein adjacent ones of said winding segments are connected to one another, said winding segments having a plurality of elongated open spaces interdigitated therebetween;
• (l) removing said blades from said slots in said cylinder and inserting said plurality of flux carrying members into said plurality of open spaces in a relationship such that at least one flux carrying member is in one said open space to provide a winding/flux carrying member assembly, said plurality of flux carrying members being formed in a substantially elongated shape and said plurality of open spaces being formed in a substantially elongated shape;
• and
• (m) thereafter providing a non-electrically conductive bonding material around said winding/flux carrying member assembly to provide a substantially rigid structure.