U.S. patent application number 11/172105 was filed with the patent office on 2005-10-27 for band coil.
Invention is credited to Frissen, Petrus Carolus Maria, Janssen, Henricus Wilhelmus Aloysius, Van Gaal, Fransiscus Marinus Andrea Maria, Vermeulen, Johannes Petrus Martinus Bernardus.
Application Number | 20050236923 11/172105 |
Document ID | / |
Family ID | 8172406 |
Filed Date | 2005-10-27 |
United States Patent
Application |
20050236923 |
Kind Code |
A1 |
Janssen, Henricus Wilhelmus
Aloysius ; et al. |
October 27, 2005 |
Band coil
Abstract
The invention relates to a method of manufacturing a band coil
by means of a material-removing process performed on the coils so
as to obtain a band coil which has a profile in the direction of
the coil axis. Such a process may be a discharge process, an
etching process or a mechanical grinding process. The obtained band
coils may have such a shape that certain coil sides are effective
whereas other coil sides are interfering as little as possible.
Such band coils can be very successful in planar motors.
Inventors: |
Janssen, Henricus Wilhelmus
Aloysius; (Eindhoven, NL) ; Vermeulen, Johannes
Petrus Martinus Bernardus; (Eindhoven, NL) ; Van
Gaal, Fransiscus Marinus Andrea Maria; (Eindhoven, NL)
; Frissen, Petrus Carolus Maria; (Eindhoven, NL) |
Correspondence
Address: |
PHILIPS INTELLECTUAL PROPERTY & STANDARDS
P.O. BOX 3001
BRIARCLIFF MANOR
NY
10510
US
|
Family ID: |
8172406 |
Appl. No.: |
11/172105 |
Filed: |
June 30, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11172105 |
Jun 30, 2005 |
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10011895 |
Dec 6, 2001 |
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6926588 |
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Current U.S.
Class: |
310/208 ; 29/606;
451/28 |
Current CPC
Class: |
Y10T 29/49066 20150115;
Y10T 29/49073 20150115; H01F 41/04 20130101; Y10T 29/4906 20150115;
H02K 15/045 20130101 |
Class at
Publication: |
310/208 ;
451/028; 029/606 |
International
Class: |
B24B 001/00; H02K
017/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 11, 2000 |
EP |
00204428.7 |
Claims
1. A method of manufacturing a coil formed by a wound band-shaped,
current-conducting foil, which coil has a coil axis, characterized
in that the coil is given a profile in a direction parallel to the
coil axis of the coil by means of a bulk-removing operation
performed on the coil turns of the coil.
2. A method as claimed in claim 1, characterized in that the
bulk-removing process is a spark erosion process.
3. A method as claimed in claim 1, characterized in that the
bulk-removing process is an etching process.
4. A method as claimed in claim 1, characterized in that the
bulk-removing process is an electrochemical process.
5. A method as claimed in claim 1, characterized in that the
bulk-removing process is a mechanical machining process.
6. A coil formed by a wound band-shaped, current-conducting foil
having winding sides and a coil axis, characterized in that at
least a portion of the winding sides is staggered with respect to
the remaining portion of the winding sides in a direction parallel
to the coil axis of the coil.
7. A coil as claimed in claim 6, characterized in that the coil has
two pairs of mutually opposed winding sides, the one pair of
mutually opposed winding sides being staggered relative to the
other pair of mutually opposed winding sides in a direction
parallel to the coil axis of the coil.
8. An assembly of at least two coils, wherein between a pair of
mutually opposed winding sides of one of the coils as claimed in
claim 7 at least one winding side of another coil is situated.
9. A translatory or rotary motor with two parts which are movable
relative to one another, the one part comprising a system of
magnets and the other part at least one coil or an assembly of at
least two coils as claimed in any one of the claims 6 to 8, while
one pair of mutually opposed winding sides of a coil lie closer to
said one part than does the other pair of mutually opposed winding
sides.
Description
[0001] The invention relates to a method of manufacturing a coil
formed by a coiled, band-shaped, current-conducting foil, which
coil has a coil axis.
[0002] The invention also relates to a coil, an assembly of such
coils, as well as to a translatory or rotary motor in which such
coils or coil assemblies are used.
[0003] The method of manufacturing a band coil as mentioned above
is known from U.S. Pat. No. 4,819,322. A metal foil insulated at
two sides is wound on a mandrel in this method. The mandrel is
removed and the wound foil is cut into a number of slices in a
direction perpendicular to the longitudinal direction of the wound
foil by means of an electric spark erosion process. The slices thus
formed are the band coils. Depending on the cross-sectional
dimensions of the mandrel, band coils obtained in this manner may
have various shapes. An example of such a band coil 1 is depicted
in FIG. 8. The coil axis 2 of a band coil is the axis which is
perpendicular to the plane of the turns 3 and is situated in the
center of the turns, i.e. in fact the axis around which the foil
was wound. In an X-Y-Z system of coordinates, therefore, the turns
lie in the X-Y plane, and the coil axis extends in the Z-direction.
The advantage of band coils over known wire-wound coils, which are
used in the great majority of cases, is the greater filling factor
of the conductor (usually copper), whereby a much higher
effectivity is achieved, but most of all whereby dissipated energy
in the form of heat can be removed much more effectively than in
wire coils, because the heat flux goes through transitions of air
and insulation with bad heat conduction in the case of wire-wound
coils, whereas the heat flux in band coils goes mainly through
copper with a much better heat conduction. The cost of manufacture
of band coils, however, is much higher than that of wire coils. A
disadvantage of the band coils known until now, however, is their
planar shape, i.e. the height of the band coil is constant. An
example of an application of a planar band coil is described in
U.S. Pat. No. 5,866,965, where a number of band coils are provided
around the stator poles of the stator of a rotary motor. The
application of the band coil is limited thereto. Coils usually have
effective and ineffective winding sides. The effective winding
sides, also referred to as coil sides, supply the desired force.
The ineffective winding sides usually have an interfering influence
on the operation of the coil. The ineffective winding sides are
bent away from the plane in which the effective winding sides are
situated in the case of wire-wound coils, or the coil is wound such
that certain winding sides have as small as possible a disturbing
influence. This is not possible in the case of band coils.
[0004] The invention has for its object to obtain a band coil in a
three-dimensional shape, such that a wide range of applications is
achieved.
[0005] The method according to the invention is for this purpose
characterized in that the coil is given a profile in a direction
parallel to the coil axis of the coil by means of a bulk-removing
operation performed on the coil turns. Coils can be obtained by
this method which are suitable for many applications, such as in
motors, but also, for example, as deflection coils in TV sets.
[0006] The bulk-removing treatment may be a spark erosion process,
for example a wire sparking process, or an etching process, or an
electrochemical process, or a machining process such as a grinding
or milling process.
[0007] The invention also relates to a coil formed by a wound
band-shaped, current-conducting foil with a coil axis. Such a band
coil is also known from U.S. Pat. No. 5,866,965. As was noted
above, such band coils have a limited range of applications owing
to their planar shape. All winding sides lie in the same plane, so
that usually two mutually opposed winding sides, or at least
portions of these winding sides, adversely affect the operation of
the coil. To increase the range of applications, the coil according
to the invention is characterized in that at least a portion of the
winding sides is staggered with respect to the remaining portion of
the winding sides in a direction parallel to the coil axis of the
coil. Ineffective portions of the winding sides as a result lie in
a different plane from the effective winding sides. Preferably, the
coil has two pairs of mutually opposed winding sides, the one pair
of mutually opposed winding sides being staggered relative to the
other pair of mutually opposed winding sides in a direction
parallel to the coil axis of the coil. As a result, the two pairs
of mutually opposed winding sides lie in different planes, so that
it is simple to position the coil in the respective application
such that only one of the two pairs of mutually opposed winding
sides is effective, and the other pair of winding sides has as
little adverse effect as possible. Such a coil may be manufactured
by the method according to the invention as described above.
[0008] The invention also relates to an assembly of at least two
coils, wherein between a pair of mutually opposed winding sides of
one of the coils according to the invention at least one winding
side of another coil is situated. The other coil may be a coil
according to the invention, but this need not necessarily be the
case.
[0009] The invention furthermore relates to a translatory or rotary
motor with two parts which are movable relative to one another, the
one part comprising a system of magnets and the other part at least
one coil or an assembly of at least two coils according to the
invention, while one pair of mutually opposed winding sides of a
coil lie closer to said one part than does the other pair of
mutually opposed winding sides.
[0010] The invention will now be explained in more detail with
reference to a few embodiments.
[0011] FIG. 1 diagrammatically shows a method by which a profile is
provided in a band coil as shown in FIG. 8,
[0012] FIG. 2 shows the profiled band coil obtained by the method
in perspective view,
[0013] FIG. 3 shows an assembly of two band coils as shown in FIG.
2,
[0014] FIG. 4 shows an assembly of three band coils as shown in
FIG. 2,
[0015] FIG. 5 shows an assembly of band coils in which profiled
band coils according to a second embodiment are used,
[0016] FIG. 6 diagrammatically and in perspective view shows a
planar motor with an assembly of band coils as shown in FIG. 4,
[0017] FIG. 7 diagrammatically shows a rotary motor in which a
profiled band coil according to the invention is used, and
[0018] FIG. 8 shows a band coil according to the prior art.
[0019] FIG. 1 diagrammatically shows how, starting from a band coil
1 as depicted in FIG. 8 and obtained, for example, by the method
described in U.S. Pat. No. 4,819,322, a profile is provided in the
winding sides. The hatched portions are removed from the band coil
by means of milling tools, for example diamond milling tools 4. If
necessary, the resulting milling surfaces may be given an
after-treatment for preventing the bands or turns of the band coil
from making contact with one another. Such a profile may
alternatively be obtained through other processes such as a spark
erosion process, an etching process, or an electrochemical process.
It will be obvious that practically all desired profiles may be
obtained. FIG. 2 shows an example of a profiled band coil 10. Seen
from the upper side, the height 14 of almost the entire long
winding sides 13a has been halved with respect to the original
height 15 of the winding sides before the treatment. The height 16
of the short winding sides 13b is also halved, but from the lower
side in this case. The cross-sectional dimension of the band-shaped
turns has remained approximately constant in this manner.
[0020] FIG. 3 shows how two such profiled band coils of FIG. 2 may
be joined together into an assembly 100. The band coil 10 is
identical to the band coil shown in FIG. 2, i.e. the short winding
sides 13b lie one band level h higher than the long winding sides
13a. The short winding sides 23b of the band coil 20 lie two band
levels 2h higher than the long winding sides 23a. The two band
coils may be laid one on the other such that one of the long
winding sides of the one band coil comes to lie exactly between the
two long other winding sides of the other band coil. The distance a
between two long winding sides of one band coil is accordingly
nominally equal to the width b of the foil package of one winding
side. As a result, all long winding sides lie in one plane and
against one another in the assembly. The short winding sides will
lie in stages one above the other, all lying above the upper side
of the long winding sides.
[0021] The embodiment of FIG. 4 is comparable to that of FIG. 3,
but here three band coils have been stacked so as to form an
assembly 200. The short winding sides 13b of the band coil 10 lie
one band level h higher than the long winding sides 13a, the short
winding sides 23b of the band coil 20 lie two band levels 2h higher
than the long winding sides 23a, and the short winding sides 33b of
the band coil 30 lie three band levels 3h higher than the long
winding sides 33a. The distance c between the long winding sides of
each band coil now is nominally equal to twice the width b of the
foil package of a winding side. In the assembly, all long winding
sides 13a, 23a, 33a lie against one another and in one plane, while
all short winding sides 13b, 23b, 33b lie in stages one above the
other and higher than the upper side of the long winding sides 13a,
23a, 33a. An application of such an assembly of band coils is shown
in FIG. 6.
[0022] FIG. 5 shows an alternative embodiment of an assembly of
profiled band coils. The shape of the three identical band coils 50
is comparable to that of the band coils 10 of FIG. 2. The two
identical band coils 1 are planar band coils as shown in FIG. 8.
The two outermost band coils 60, 61 are somewhat different in
shape. In these band coils, one of the long winding sides 63a.sub.1
lies higher than the other long winding side 63a.sub.2. In the
assembly 30, the band coil 60 is mirrored symmetrically in its
position with respect to the band coil 61. The distance c between
the long winding sides of each band coil is twice the width b of
the foil package of a long winding side again, so that two winding
sides, each of a different band coil, will lie between the long
winding sides of a band coil each time in the assembly, with the
exception of the long winding sides 63a.sub.1 of the outermost band
coils. These winding sides lie above the upper side of all other
long winding sides, as do a number of short winding sides. In this
manner, therefore, twelve long winding sides lie next to one
another in one and the same plane in this assembly.
[0023] FIG. 6 diagrammatically shows the principle of a planar
motor. In such a motor, two parts 400, 500 which are movable
relative to one another, with the one part 400, usually a
stationary part, comprising a system of magnets 410 of alternating
N and S poles, and the other, movable part 500 comprising a system
of coils 510. Such a planar motor is known from WO . . . (being the
PCT patent application EP 00/07970=PHN17.621, which is to be
replaced in due time by the publication no. WO . . . of the PCT
application). The system of coils for this planar motor is formed
by four coil block units 511a, 511b, 511c, 511d, each unit
comprising two coil blocks 512 situated next to one another. Each
coil block has six current conductors which are present in the
magnetic field of the system of magnets. The current conductors
accordingly are the long, effective winding sides or coil sides of
the coils. The current conductors of the coil block units 511a and
511c extend in the X-direction, whereas the current conductors of
the coil block units 511b and 511d extend in the Y-direction. The
current conductors are supplied from a 3-phase system. The movable
part 400 can move in a controlled manner in the X-Y-plane
immediately above the stationary part 500 comprising the system of
magnets through commutation of the current. Lorenz forces exerted
on the coil block units 511b and 511d cause a movement in the
X-direction, and Lorenz forces exerted on the coil block units 511a
and 511c cause a movement in the Y-direction. Each coil block in
this application is formed by the assembly 200 of coils as depicted
in FIG. 4. The long winding sides of the coils lie immediately
above the surface of the magnets of the system of magnets. The
Lorenz forces arising here are the forces which render it possible
to obtain a controlled movement. Lorenz forces also arise at the
short winding sides. These forces have a disturbing effect on the
desired movement. To reduce this disturbing effect, the Lorenz
forces at these short winding sides must be as small as possible.
This is achieved in that the short winding sides are brought to a
greater distance from the surface of the system of magnets, and
thus farther away from the influence of the magnetic field. This is
possible with the coils in accordance with the present invention.
Obviously, it would also be possible in the case of the known
wire-wound coils to bend away said short winding sides from the
influence of the magnetic field. As was noted above, however, these
wire coils are much less effective, i.e. the force supplied by a
wire coil is much smaller than the force supplied by a band coil.
This is caused on the one hand by the higher filling factor of
copper of band coils compared with wire coils, and on the other
hand by a much greater current density being practicable in band
coils as a result of a much more efficient heat removal. The
assembly of band coils shown in FIG. 5 might also be used in the
planar motor of FIG. 6. Such an assembly then forms one coil block
unit 511(a, b, c, or d).
[0024] Finally, FIG. 7 shows an example of a band coil according to
the invention used in a rotary motor. The stator 70 is formed by a
hollow cylinder 71. The inner surface of the cylinder is provided
with a number of stator poles 72 which extend in longitudinal
direction of the cylinder. The stator poles 72 have a bent shape,
in fact they form part of a cylinder. The stator is made of a
magnetizable material, such as iron. The band coils 73 have a bent
shape, i.e. the shapes of two mutually opposed winding sides 74b
are adapted to the shape of the stator poles 72. The other winding
sides 74a are straight or faintly curved over the width of this
winding side. The rotor 75 is provided with rotor poles 76. The
rotor is also made of a magnetizable material, such as iron.
Further details on the operation of such a rotary motor are given
in U.S. Pat. No. 5,866,965. It is obviously also possible to use
one or several assemblies of band coils similar to those shown in
FIGS. 3 to 5, but with curved winding sides, in a rotary motor in
such a manner.
[0025] Since band coils according to the invention may be given any
three-dimensional shape, their application in very complicated
motors, which have to enable both rotary and linear movements, is
possible.
[0026] Band coils according to the invention may also be
successfully used for the deflection of electron beams in TV sets.
The band coil may be brought into a shape in which all coil sides
are effective.
* * * * *