US 6,249,204 B1Granted

Apparatus and method for continuous magnetic core winding of electrical transformers and inductors

AssigneeGeneral Electric Company

InventorsJavier Larranaga, Joe Criniti, Farshid Attarian

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Abstract

An apparatus for winding the magnetic core of an electronic transformer about a pre-formed wire coil, the apparatus comprising a first member, a second member, and a locking device for aligning and fastening said first member to said second member. The first member and the second member each further comprising a winding member, a first flange disposed at a first end of said winding member, and a second flange disposed at a second end of the winding member. A method of continuously winding a magnetic material onto a bobbin assembly to form a wound core of an electrical transformer is provided and comprises forming a bobbin assembly about a pre-formed wire coil, fixing a leading edge of the magnet material to the bobbin assembly, and rotating said bobbin assembly about the pre-formed wire coil to wind the magnetic material onto the bobbin assembly.

Claims19

Dependent claims

An electrical transformer comprising:

a bobbin assembly including:
a first bobbin member;
a second bobbin member,
each of the first and second bobbin members including first and second flange members defining first and second ends of the bobbin members and a smooth uninterrupted winding member extending between the first and second flange members, the first and second flange members each comprising a serrated semicircular outer periphery, a semicircular inner periphery, and two flat connecting peripheral sections connecting the semicircular outer periphery with the semicircular inner periphery;
each of the first and second flange members including a locking mechanism having a locking post and a locking pin for aligning and fastening the first bobbin member to the second bobbin member, wherein the two flat connecting peripheral sections of each of the first and second flange members of each of the first and second bobbin members abut flushly, and the serrated semicircular outer periphery of each of the first and second flange members of each of the first and second bobbin members form a serrated circular outer periphery on opposite ends of the bobbin assembly;
and
a coil disposed about the first and second bobbin members, wherein a portion of the coil is captured between the first and second bobbin members.

4 more elements

A method of continuously winding a magnetic material onto a bobbin assembly to form a wound core of an electrical transformer, the method comprising:

providing a first bobbin member and a second bobbin member with each a first flange and a second flange on opposite ends of their respective bobbin members, the first and second flanges each having a serrated semicircular outer periphery, a semicircular inner periphery, and two flat connecting peripheral sections connecting the semicircular outer periphery with the semicircular inner periphery;
providing each first flange and second flange with a locking mechanism for aligning and fastening the first bobbin member to the second bobbin member;
providing each of the first and second bobbin members with a smooth uninterrupted winding member extending between the first and second flanges;
fastening the first bobbin member to the second bobbin member by abutting the two flat connecting peripheral sections of the first flange of the first bobbin member to the two flat connecting peripheral sections of the first flange of the second bobbin member, abutting the two flat connecting peripheral sections of the second flange of the first bobbin member to the two flat connecting peripheral sections of the second flange of the second bobbin member, and locking the first bobbing member to the second bobbin member by mating a first locking post extending from the first bobbin member with a first locking pin formed on the second bobbin member and mating a second locking post extending from the second bobbin member with a second locking pin formed on the first bobbin member to form a bobbin assembly so that a portion of the coil is captured between the first and second bobbin members;
fixing a leading edge of said magnetic material to the bobbin assembly;
and
employing said flanges for rotating said bobbin assembly about said preformed coil to wind the magnetic material about the winding members of the bobbin assembly.

4 more elements

Dependencies are inferred from the claim text.