U.S. patent number 3,662,460 [Application Number 05/082,444] was granted by the patent office on 1972-05-16 for method of making a random wound encapsulated coil.
This patent grant is currently assigned to Westinghouse Electric Corporation. Invention is credited to Thomas J. Daley.
United States Patent |
3,662,460 |
Daley |
May 16, 1972 |
METHOD OF MAKING A RANDOM WOUND ENCAPSULATED COIL
Abstract
A random winding is located on a spool having a central support
and having end flanges provided with ribs or perforations. An
insulating material in fluid form such as an epoxy resin is applied
under pressure to the winding and spool to flow between the ribs or
through the perforations to compact the winding. This provides a
continuous layer of the insulant in contact with end windings and
assures good resistance to electric breakdown. Insulant may be
introduced in a similar way between the central spool support and
the winding.
Inventors: |
Daley; Thomas J. (Raleigh,
NC) |
Assignee: |
Westinghouse Electric
Corporation (Pittsburgh, PA)
|
Family
ID: |
26767467 |
Appl.
No.: |
05/082,444 |
Filed: |
October 20, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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659216 |
Aug 8, 1967 |
3559134 |
|
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Current U.S.
Class: |
29/605; 336/96;
336/198; 336/205; 336/208 |
Current CPC
Class: |
H01F
5/02 (20130101); H01F 41/127 (20130101); H01F
41/10 (20130101); Y10T 29/49071 (20150115) |
Current International
Class: |
H01F
41/10 (20060101); H01F 41/12 (20060101); H01F
5/02 (20060101); H01f 007/06 () |
Field of
Search: |
;29/605,602
;336/96,198,205,208 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Campbell; John F.
Assistant Examiner: Hall; Carl E.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of my copending patent application, Ser. No.
659,216 filed Aug. 8, 1967, now U.S. Pat. No. 3,559,134.
Reference is made to applicant's copending patent application, Ser.
No. 659,217, now U.S. Pat. No. 3,496,504, filed concurrently
herewith which is directed to a terminal assembly for an
encapsulated coil.
Claims
I claim:
1. The method of constructing an encapsulated coil assembly which
comprises constructing a unit including a spool having a central
support and a flange at a first end of the support, winding turns
of a coil around the central support with end turns of the coil
touching at least a portion of said flange and with substantial
portions of the end turns exposed to the exterior of said coil and
spool, moving said end turns away from said flange in a direction
parallel to the longitudinal axis of said spool such that said end
turns are in a spaced relationship with said flange, and securing
said coil and said end turns when in said spaced relationship to
said spool.
2. The method claimed in claim 1 wherein said step of winding
exposes substantial portions of the end turns to the exterior of
said coil and spool unit, and said moving comprises the step of
flowing under pressure a hardenable liquid insulating material
between said end turns and said flange to mold said insulating
material in intimate engagement with said end turns, whereby upon
hardening said insulating material forms a continuous solid
insulating layer intermediate said end turns and the flange.
3. The method of claim 2 wherein said liquid insulating material is
flowed and subjected to pressure over the exposed surface of said
coil to encapsulate the coil, said flowing under pressure
compressing the coil turns.
4. The method of claim 3 wherein said winding of turns spaces the
turns from substantial portions of the central support to permit
introduction therebetween of said insulating material, said flowing
step being effective for forcing said insulating material between
the turns and said central support in intimate engagement with said
turns.
5. The method of claim 2 wherein said central support comprises a
tubular member, and said spool has a flange at a second end of the
support, each of said flanges having plural perforations extending
through the flange parallel to said tubular member, said flowing
including the flowing under pressure of the insulating material
from the exterior of said spool through said perforations to
compress the coil.
6. The method of claim 1 wherein said spool has a second flange at
a second end of the support, said winding step positioning end
turns of the coil adjacent the second flange, said moving step
spacing said end turns from the second flange.
7. The method of claim 6 wherein said step of winding exposes
substantial portions of the end turns adjacent each of the flanges
to the exterior of said coil and spool unit, and said moving
comprises the step of flowing a hardenable liquid insulating
material between each of said flanges and the adjacent end turns
under a pressure sufficient to compress the coil turns and to mold
a continuous layer of said insulating material into intimate
engagement with the end turns adjacent each of the flanges, whereby
upon hardening said insulating material forms a solid continuous
insulating layer intermediate each of said flanges and the adjacent
end turns.
8. The method of claim 7 wherein said winding step is random
winding, and each of said flanges has an irregular surface engaging
portion of the adjacent end turn surface and exposing other
portions of such adjacent end turn surface, whereby said liquid
insulating material flows into engagement with the exposed other
portions and under pressure forces the end turns away from the
flanges.
Description
BACKGROUND OF THE INVENTION
This invention relates to random wound coils and it has particular
relation to random wound coils which have a high resistance to
voltage breakdown. Although the invention is applicable to coils
employed in various devices it is particularly suitable for voltage
coils of induction watt-hour meters and will be described as
applied to such voltage coils.
It has been common practice to employ a layer-wound construction
for the fine wire voltage coils of watt-hour meters. Such coils can
be designed readily to offer high resistance to internal voltage
breakdown.
Random wound coils offer a number of advantages such as smaller
size and simplicity of manufacture. However it has been very
difficult heretofore to obtain high resistance in such coils to
internal voltage breakdown. In an induction type watt-hour meter a
voltage coil may be subjected to very high voltages as a result of
lightning surges, switching surges or other transients.
SUMMARY OF THE INVENTION
In accordance with the invention, turns of a random wound coil are
spaced from an adjacent surface of the supporting spool or bobbin.
Preferably, an insulating molding material is introduced into the
space so provided for the purpose of compacting the turns of the
coils and substantially eliminating air spaces. The molding
material is forced into intimate contact or engagement with the end
turns of the coil and provides a continuous insulating surface
between such turns and an adjacent portion of the spool or bobbin
and between adjacent or closely positioned turns of the coil. This
materially raises the breakdown voltage of the coil.
It is an object of the invention to provide a process for
constructing a random wound coil having high resistance to voltage
breakdown.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the invention will be apparent from the following
description taken in conjunction with the accompanying drawings, in
which:
FIG. 1 is a view in elevation with parts broken away of an
induction watt-hour meter embodying the invention;
FIG. 2 is a view in elevation with parts broken away of the voltage
coil employed in the meter of FIG. 1 associated with encapsulating
apparatus;
FIG. 3 is a view in perspective with parts broken away of a spool
employed for the coil of FIGS. 1 and 2, and
FIG. 4 is a view in end elevation showing a modified spool
construction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 represents an induction watt-hour meter having an
electromagnet 1 which provides an air gap for an electro-conductive
disc or armature 3. The electromagnet 1 includes a magnetic
structure generally formed of laminations of soft magnetic steel
and providing a voltage pole 5 and current poles 7. A voltage
winding 9 surrounds the voltage pole and current windings 11 are
associated with the current poles 7. Structures of this general
type are described in the Electrical Metermen's Handbook, 7th
edition, published in 1965 by the Edison Electric Institute of New
York City. As pointed out in this handbook, pages 673 and 674, the
meter stator may have a 10-kilovolt impulse withstand level.
The voltage coil 9 has a large number of turns of small diameter
electroconductive wire which is of the insulated or enameled type.
As an example a voltage coil designed for energization from a
240-volt alternating current circuit may have 5,500 turns of No. 33
wire (American Wire Gage).
The voltage coil 9 is of the random wound type wherein the turns
are wound on a spool or bobbin having a central support 13 and a
pair of flanges 14 and 15. The central support 13 is in the form of
a tubular sleeve which may be of circular cross section but more
commonly has a rectangular cross section adapted to receive snugly
a voltage pole 5 of rectangular cross section.
If the turns are wound on a conventional spool with the end turns
in direct engagement with the flanges of the spool it will be found
difficult to obtain the desired level of resistance to voltage
breakdown. One of the principal breakdown points in a random wound
coil of conventional construction is between the start and finish
layers or intermediate layers at the interspace of the enameled
wire and the spool flange. If such a coil is encapsulated the
forces generated during the encapsulation tend to reduce the start
to finish distance and this reduction decrease the breakdown
level.
In accordance with the invention the end turns of the coil are
spaced from the flanges by a layer of insulating material which is
molded into intimate contact with the end turns. To this end the
flanges may be provided with a large number of ribs 17 as shown in
FIG. 3. These ribs space the end turns of the coil sufficiently
from substantial portions of the flanges to permit the introduction
of hardenable insulating material in liquid form into the spaces
established by the ribs. The material may be a solid at room or
ambient temperature which becomes liquid under the temperature and
pressure conditions present during such introduction.
After the winding is applied to the spool the resultant structure
is placed in a mold 19 having a cavity corresponding to the desired
resultant outline of the coil. The mold includes a top 19A, a
bottom 19B and a core 20 for the central support to prevent entry
of encapsulating material into the central support. The mold also
has an inlet 21 through which suitable encapsulating material may
be introduced by a transfer ram 22. The encapsulating material is
applied in liquid form through conventional runners and gates and
is designed to harden in place to provide good insulation for the
winding. Conveniently the encapsulant may be solid under ambient
temperature conditions encountered by the meter during use, but may
be liquid under the temperature and pressure conditions employed
for encapsulation. Nylon and a thermosetting polyester resin are
examples of suitable encapsulating materials. Preferably the
encapsulating material is an epoxy resin provided with a filler
such as fiberglass.
When the encapsulating material is applied in liquid form to the
mold it flows between the ribs 17 on the flanges into direct
engagement with substantial portions of the end turns of the
winding.
In a preferred embodiment the encapsulating material is forced into
the mold under substantial pressure such as 2,000 lbs. per square
inch. Such pressure tends to compact the windings of the coil and
to force the end turns away from the associated flanges. This has
the effect of introducing a continuous layer of insulating material
in direct contact or engagement with the end turns and located
between the end turns and the associated flanges. The encapsulating
material is now permitted to harden and if the material is of the
thermosetting type heat may be applied to expedite such
hardening.
The introduction of the encapsulating material into direct
engagement with the end turns has made it possible to increase the
breakdown voltage of the random wound coil to more than 225 percent
of the values previously obtained, and increases of more than 300
percent have been obtained. For example 240-volt watt-hour meter
voltage coils have been constructed with a breakdown voltage of the
order of 23 kilovolts.
The elimination of air spaces resulting from the intimate contact
of the encapsulant with the wire turns provides the additional
benefit of reducing the harmful effects of corona. This elimination
may be further assisted by utilizing the well-known vacuum molding
techniques during encapsulation.
It will be noted that the encapsulating material together with the
spool forms a complete encapsulation for the voltage coil. If
desired the encapsulating material may be introduced between the
turns and the central support 13 to increase the insulation between
the turns and the voltage pole which is located within the central
support. To this end ribs 17a on the outer surface of the central
support may be provided to space adjacent coil turns from
substantial portions of the support.
When the encapsulating material is applied it flows into the spaces
between the ribs 17a of the central support and compacts the coil
to form a substantial layer of insulation between the coil and the
central support. For many applications these additional ribs 17a
are not required.
In the modification of the invention shown in FIG. 4 the ribs on
the flanges are replaced by holes 23. Thus in FIG. 4 the flange 15
of FIG. 3 is replaced by a flange 15a of sheet insulating material
having holes 23 which extend through the flange in a direction
parallel to the axis of the central support to expose substantial
portions of the coil end turns to the exterior of the spool. When
the spool of FIG. 4 and the random wound winding thereon are
encapsulated in the manner discussed above the liquid encapsulating
material flows through the holes 23 into contact with the end
turns. When the encapsulating material is subjected to pressure,
the windings are compacted and a continuous layer of insulating
material is molded into intimate engagement with the adjacent end
turns.
Although the invention is particularly suitable for induction
watt-hour meters the principle thereof may be employed on any
random wound wire arrangement which requires high resistance to
internal voltage breakdown. Thus it may be applied to a coil or a
transformer which has insulation molded by injection, transfer or
compression molding. Improvements in breakdown level also are
obtained when the principle is applied to potted or impregnated
coils, wherein the encapsulant may be permitted to flow by gravity
around the coil.
The ends of the coil may be made available for electrical
connections or terminals in any conventional manner. In a preferred
embodiment the flange 14 is provided with a slot 25 through which
the inner end of the coil extends. This end is secured in a
solderless connector 27 located on one end of a sealing plate 29.
Another solderless connector 31 is secured to the opposite end of
the plate 29 and extends beyond the encapsulating material to
receive an external electric lead. As shown in FIG. 2 the mold 19
has a pocket 33 which permits encapsulating material to flow around
the solderless connector 27, and its connection together with part
of the plate 29 while leaving the solderless connector 31 free to
receive an external lead. The mold is of multi-part construction
and provides parting surfaces engaging the plate 29. Thus the plate
29 provides sealing surfaces engaging the adjacent parts of the
mold. This terminal construction is presented in applicant's
aforesaid copending patent application. A similar terminal
construction 27a, 29a, 31a is shown for the other end of the
coil.
In order to hold the terminal assemblies during the molding
operation, the flange 14 has two pockets 35 and 35a proportioned to
receive the connectors 27 and 27a respectively.
The complete spool may be constructed in any suitable manner.
Preferably the spool including, the central support 13, the flanges
14, 15, the ribs 17, the pockets 35, 35a, and the slot 25 are
molded from a suitable insulating material which may be similar to
that employed for encapsulation provided that it is capable of
retaining its shape during the conditions of encapsulation. On its
exterior face each flange may have a rectangular spacer adjacent
the central support to space the flange correctly from the adjacent
mold surface and to provide a barrier preventing entry of the
encapsulant within the central support or core. Thus a spacer 14'
is formed integrally on the face of the flange 14.
In a few applications exposed terminals may not be desired. In such
a case the solderless connectors may be omitted and electric lead
wires may be soldered to the coil ends. The solder joints are
covered by the encapsulant.
* * * * *