Abstract: A high voltage reactor includes a plurality of angularly spaced columns for supporting the layers of a disk winding in vertically spaced relation. Each of the columns is comprised of a monolithic casting of an insulative material and pairs of angularly spaced, rigid plastic casting forms disposed between each winding layer. The form pairs are in vertical alignment to establish requisite layer-to-layer and turn-to-turn separations, as well as to provide the sidewalls of a casting mold utilized in forming the column. The forms thereafter remain in place to constitute the column sidewalls.

Abstract: An induction heating coil for use in a cooking range or the like. The coil is defined by a flat spiral of electrically conducted wire having at least three radially related sections including a radially outermost section having closely spaced turns, a radially innermost section having closely spaced turns, and a radially intermediate section having widely spaced turns. In one form, the intermediate section turns are uniformly widely spaced. In another form, the intermediate section turns are arranged in widely spaced groups. The disclosed configurations provide a substantially uniform power transfer to the element being heated, such as a ferromagnetic utensil.

Abstract: A transformer has an insulator interposed between respective primary and secondary coils wound on a coil bobbin which has an axial winding part and opposing radially extending flanges. The insulator is made from a continuous sheet of material which is corrugated to provide an insulating base having a width larger than the width of the winding part of the coil bobbin and from a continuous, plastic insulating sheet member having substantially the same width as the winding part. The corrugated insulated base material and insulating sheet member are wound between the primary coil and the secondary coil and the corrugated insulating base is bent at both side edges to be L-shaped to intimately fit to the inner surface of the flanges of the coil bobbin so as to provide an insulator which positively prevents coil wire at each end portion of the coil from dropping out of alignment with respective coil turns.

Abstract: Disclosed is a conductor coated with a fused and cured powder applied insulating coating over which is a coating of an ultraviolet B-stageable, thermally C-stageable liquid resin. The coating is cured to the B-stage and strands of the conductor are placed side-by-side. The coating is then cured to the C-stage which fuses the strands of the conductor into a solid mass. The adhesive coated conductors may be used to form transformer coils, transposed cables, or other articles.

Abstract: A one-half turn inductor is formed in a mold having a series of spaced ribs forming grooves therebetween, a U-shaped coil has its bight portion positioned in a selected one of the grooves corresponding to the inductance value of the inductor with the legs of the coil projecting beyond the cavity. Plastic is introduced into the cavity to create a coil form with the coil embedded in the plastic. The ribs and grooves form an inspection window consisting of spaced parallel rungs, one of said rungs being an exposed segment of the coil, the remainder being plastic.

Abstract: A coil structure for cellulose-free transformer coils characterized by at least three helically wound layers disposed in a reversal pattern with wedge-shaped resinous insulators between each layer.

Abstract: A coil structure for cellulose-free transformer coils characterized by a plurality of helically wound layers disposed in a zig-zag pattern with wedge-shaped resinous insulators between each layer.

Abstract: An electromagnetic assembly includes a core having an inner cylindrical portion and an outer cylindrical portion spaced from the inner cylindrical portion to provide space or a cavity for a bobbin. The bobbin is adapted to fit into the space provided in the core and has an elongated cylindrical body, a coil of wire wound around the body, and a flange at each end of the body for holding the coil on the body. A portion of one flange extends from the bobbin and overlaps a portion of the core. The bobbin is held in the core cavity by an interference fit provided between the overlapping, extended flange portion and the overlapped core portion.

Abstract: A tape useful for bonding electrical coils can be made flexible upon cure by using an impregnating varnish composition comprising a blend of (A) an alkyd component reaction mixture containing at least 29 equivalent % of fatty acid, and (B) an alkyl acrylate monomer.

Abstract: An electrically insulated coil comprising a coil; and a mica tape wound around said coil and containing a resin composition; said resin composition including an epoxy resin, a curing catalyst consisting of an aluminum compound, and a curing accelerator selected from the group consisting of a silane compound having a hydroxyl group and a polysiloxane compound having a hydroxyl group, said curing catalyst being added in an amount of 0.1 to 5% by weight based on said epoxy resin, said curing accelerator being added in an amount of 0.1 to 10% by weight based on said epoxy resin, and said resin composition being cured by heating after said mica tape is wound around said coil.

Abstract: The pulse transformer consists of a closed toroidal core (30), the primary winding (31) and secondary winding (32) of which are fashioned as multilayer, flexible printed circuit boards. These circuit boards have the shape of flat strips and are bent into loops. By means of pins (36-39 and 46-49, respectively), they are connected mechanically and partially electrically to a supporting printed circuit board (11). The pins connect the conductor tracks of the central layer of the flexible printed circuit boards with respectively one winding, whereas the upper and lower conductive layers shield the windings against electromagnetic interferences coming from the outside.The pulse transformer is suitable as an isolation transformer for the transmission of rapid digital signals arriving, for example, via a coaxial line (20).

Abstract: The present invention relates to a slotless, brushless motor comprising a permanent magnet rotor rotationary together with a shaft and a stationary armature coil disposed in opposition to the rotor.The armature coil comprises a coil portion concentrically wound, an adjacent coil portion formed in sequence from the coil portion and concentrically wound, a coil performed on a plane by a plurality of the coil portions, N coils (N is integer) laid on each other and different in a phase respectively, sheets disposed between said N coils and a supporting member supporting the coils and the sheets made integral.

Abstract: An electrically insulated coil is composed of a coil and a mica tape containing a first resinous composition, wound upon the coil; the resinous composition containing a maleimide compound, an epoxy resin, a curing catalyst consisting of an aluminum compound, and a curing accelerator selected from the group consisting of a silane compound having a hydroxyl group and a polysiloxane compound having a hydroxyl group; the curing catalyst and the curing accelerator each being in an amount of about 0.0001 to 5% by weight based on the total amount of the maleimide compound and the epoxy resin; and the resinous composition being cured by heating after the mica tape is wound around the coil.The electrically insulated coil may further contain a second resinous composition comprising an epoxy resin and an acid anhydride, the second resinous composition impregnating the mica tape after the mica tape is wound around the coil, and being heat-cured together with the first resinous composition.

Abstract: A transformer winding, made as a layered winding with striplike conductor insulated with at least one strip of insulation folded about the conductor, and a process for making the same, are disclosed. To make possible a fully automatic manufacture of the winding with sufficient mechanical strength and uniform impregnation, the insulation strip, in addition to insulation of the conductor, constitutes likewise the insulation of the layers. At the periphery of a winding layer there are punctate bonding places at predetermined distances only on the outside of the conductor insulation. The cross section of the layered winding may be essentially trapezoidal with the transition to the free outer end comprising one or more circular arcs with different radii.

Abstract: In winding the stator of a long stator linear motor without iron, the conductors of the traveling wave winding in the stator are designed as round jacketed lines which are fixed to a non-magnetic winding support by cross-bars and retained in place by hardenable non-magnetic material. The conductors of the traveling wave winding are approximately flush with the outside surface of the stator which is disposed opposite an exciter magnet on a moving vehicle.

Abstract: An improved normal or superconductive field coil constructed so that individual coils are both axially and radially stable. The individual coils are provided with a holding cylinder at each end with the conductor ends being fixed to the holding cylinder. In another embodiment an electrically insulating, reinforcing cylinder is fixed to the outer periphery of the coil.

Abstract: This invention relates to electrical articles having an electrical coil such as high-tension transformers, ignition coils and the like which are excellent in withstand voltage and endurance; and to a method for manufacturing the same. These electrical articles have an electrical coil in which a sheet material such as paper, cloth or non-woven fabric comprising cellulose as major constituent is used as at least a part of interlayer insulator. Said sheet material is characterized by being impregnated with one or more pretreating resins selected from the group consisting of phenolic resins, s-triazine ring compound resins, and phenol-s-triazine ring compound co-condensation resins and further impregnated with a thermosetting resin composition containing an epoxy resin, unsaturated polyester resin, 1,2-polybutadiene resin or silicone resin, said resin being hardened.

Abstract: Electrical apparatus includes electrical coil means formed of multiple turns of enamel-covered electrical wire axially mounted on a core of magnetic material in electromagnetic energy coupling relationship therewith, and a relatively flat flexible electrical cable containing a plurality of spaced parallel conductors extending between the cable ends contains a loop shaped portion extending about an axis of said core over an arcuate distance greater than 180 degrees.

Abstract: A resinous composition, suitable as a high voltage insulation for electrical members, is made from an admixture containing: 100 parts of an epoxy resin, about 25 to 200 parts of an acid anhydride reactive with the epoxy resin, about 0.01 to 2.0 parts of chromium or zirconium acetylacetonate, acting as a latent accelerator and about 0.3 to 30 parts of a selected organic carboxylic acid, acting as a co-accelerator.

Abstract: A highly fluid, solventless, resinous, impregnating and coating composition, suitable as a high voltage insulation for electrical members, is made from an admixture containing: 100 parts of an epoxy resin, about 25 to 200 parts of an acid anhydride reactive with the epoxy resin, and about 0.002 to 1.00 part of a selected metal acetylacetonate, acting as a latent accelerator.

Abstract: A transformer, one winding of which consists of a single turn which is formed by a conductor which is bent to be U-shaped and which is embedded in a body of synthetic material, the two ends of said conductor projecting outside the body and forming connection pins.

Abstract: Electrical winding assembly constructed by (A) winding an electrical conductor into a plurality of radially-spaced layers about an axis, (B) disposing electrical insulating sheet material, which has dry, heat-reactive resin material disposed at discrete areas on at least one side thereof, between the layers of the electrical conductor, (C) applying a slurry formed of solid, heat-reactive resin particles suspended in a non-aqueous liquid carrier, wherein the liquid is chemically inert for the resin particles suspended therein so as not to dissolve or enter into a reaction with the resin, at predetermined locations between certain of the layers of the electrical insulative material and the electrical conductor and (D) heating the electrical winding assembly at a predetermined temperature for a predetermined period of time sufficient to volatize the non-aqueous liquid carrier and to cause the resin on the electrical insulative material and in the slurry to soften and form cohesive bonds between adjacent layers o

Abstract: A potted transformer winding and a method of manufacturing the same are disclosed. The method of manufacture includes the steps of inserting a temporary core pin in a hollow bobbin, winding a first coil of wire on the bobbin, placing a bobbin sleeve over the bobbin, and winding a second coil of wire on the sleeve to form a transformer winding assembly. Other sleeves and coils can be provided if desired. The transformer winding assembly is located in the interior of a casing, the casing and winding are heated, the casing interior and winding are subjected to a vacuum, and a potting compound is introduced into the casing interior in continuation of the vacuum and heat. The potting compound then flows between the core pin and the bobbin to form an electrically insulative coating inside the bobbin hollow. After the casing, winding and potting compound have cooled, at least one hole is formed in the casing adjacent an end of the pin and the pin is removed from the bobbin casing.

Abstract: High voltage solid dielectric insulation system transformers and inductors have been designed and produced by a process which results in a substantial improvement in the high voltage, size and weight characteristics of magnetic components prepared therefrom.

Abstract: An EMR coil assembly having a split housing including a coil-retaining body member and ring member attached thereto, the EMR coil assembly including a coil having a plurality of polyimide face sheets disposed between a polyester face sheet forming the outer wear surface of the coil and a major surface of the coil.

Abstract: A synthetic resin packed coil assembly formed by a wound spiral of a number of bundled turns of insulated wire comprises at least one layer enveloping the bundled turns of insulated wire of the wound spiral. This layer is composed of a synthetic resin reinforced by a high strength fibrous material and is formed by first winding the high strength fibrous material around the bundled turns of insulated wire of the wound spiral, subsequently impregnating a solution of the synthetic resin and finally allowing the synthetic resin to harden.

Abstract: A magnet winding method is provided wherein the individual pancakes are fabricated such that adjacent pancakes have oppositely spiraled grooves that begin and end at the same relative locations on the pancakes. Holes through the pancakes are provided at each end of the spirals that permit winding the entire magnet without a single splice.

Abstract: A dry insulated, impulse voltage resistant, multi-layer series wound coil having air ducts between layers for use in transformers, reactors, and the like is made with minimum solid insulation spacing between adjacent conductors and maximum air spacing radially between coil layers. The method of making includes winding on a form of alternate layers of insulation and conductors. After one layer of winding is complete, cloth-wrapped duct-forming molds are supported on the windings and further insulation and conductors are wound around the whole assembly. When the desired number of layers is complete, the assembly is vacuum cast in a resin and the forms and the molds are then removed.

Abstract: The induction coil of this invention is wrapped on a non-metallic core with convolutions of the coil adjacent to one another. An adhesive tape is applied over the convolutions with a lapped seam of the tape and with the tape preferably extending beyond both ends of the coil in order to hold the convolutions of coil against moving with respect to one another while the coil is being transported from the winding step to the next operation in which a jacket is molded over the coil in a cavity of an injection molding machine.

Abstract: An electrical conductor having a plurality of sides which define a generally rectangular cross-sectional configuration is coated with an electrical insulating material on all sides. An adhesive coating having a predetermined thickness and width dimension is applied to only a selected side of the conductor. The thickness of the adhesive is reduced, and the width of the adhesive coating is increased, when the conductor is wound into a coil having a plurality of turns, and the coil is heated to fuse the adhesive coating and provide an adhesive bond between the turns of the coil.

Abstract: A flexible, nontacky prepreg for use in bonding high voltage coils and inner cooling channels which comprises a fibrous mat material containing a high molecular weight epoxy and a sterically hindered anhydride. The resin comprises approximately 25 to 500% by weight of the fibrous mat material.

Abstract: A transformer is disclosed in which an insulating material having a thermal conductivity higher than 10.sup.-3 cal/cm.sec..degree. C is interposed between a coil and a core so that transfer of heat generated in the coil to the core may be attained at a higher rate and consequently efficient heat dissipation may be effected. The diameters of conductors used may be reduced so that a transformer compact in size and light in weight may be provided.

Abstract: A coil suitable for use as a radio component, for example, an FM trimmer coil, is formed of a self-supporting wire coil enclosed in a housing comprising two halves molded of insulated material and ultrasonically welded together to captivate the coil, ribs on the housing interior extend between turns of the coil in contact therewith to securely contain the coil turns and prevent axial movement thereof. Optionally, a threaded tuning slug is adjustably located within the coil supported by the inner ends of the ribs at a fixed spacing from the coil. Integral coil terminals extend through the housing and a window in the side of the housing allows an additional terminal to be welded to a coil turn intermediate the ends of the coil.

Abstract: A wire is wound on a coil body form about a removable mandrel in a first layer in which the turns abut one another. A guide ring reverses the direction of lead of the wire to form a second, overlying layer in which the turns are spaced a short distance apart from one another. The final turns of the outer layer engage about the coil form. A casting agent applied to the coil penetrates the turns of the second and first layers and is hardened. The mandrel is removed and the coil is self-supporting, for use as in a moving-coil motor. A fiberglass sheet may optionally be applied about the first layer before the second layer is wound thereover to increase the strength of the coil.

Abstract: Insulated wire coated with a bonding material is formed into cables and wound in an appropriate chamber. A pressurizing material is utilized to compress the wires in the chamber. The pressurizing material is then hardened to maintain the wires in the compressed state. Heat is then applied to cause the bonding material to bond the wires together and rigidly maintain them in the positions they occupy when compressed.

Abstract: An induction cooking appliance for operation at ultrasonic frequencies and including an improved work coil coupled in a solid state inverter circuit to generate an ultrasonic frequency magnetic field which is coupled to a metallic utensil through a non-electrically conductive cooktop. Coil losses are minimized, and coupling efficiency increased by forming the coil of solid conductor wound in a loose spiral, with the pitch of the spiral being related to the radial thickness of the conductor by a factor falling within a predetermined range. The loosely wound coil is held in a grooved dielectric support which insures proper turn spacing for the life of the appliance and which is immune to high temperatures which may be developed during operation of the coil. Means are provided under the support to minimize stray radiation and limit inductance variations which might otherwise result from nearby metallic members.

Abstract: A flexible, nontacky prepreg for use in bonding high voltage coils and inner cooling channels which comprises a fibrous mat material containing a high molecular weight epoxy and a sterically hindered anhydride. The resin comprises approximately 25 to 500% by weight of the fibrous mat material.

Abstract: High frequency electrical coils are commonly made out of Litz wire. If the coil is baked and an aqueous phenol solution is pumped through a nylon tube making up the structural core of the Litz wire, the tube will be dissolved out, thereby yielding an unobstructed opening through which a cooling fluid may be pumped. The resultant coil has a vastly improved heat conduction and can tolerate substantially higher currents.

Abstract: A porous, electrical insulating adhesive substrate is made, by uniformly coating a flexible, porous sheet material with adhesive resin particles having an average particle size of between about 37 to 420 microns, the adhesive coating covering from about 5 to 50 percent of the sheet material area in a non-patterned random distribution, and then heating the coated sheet material between about 85.degree. to 250.degree.C, forming a discontinuous 0.

Abstract: Electrical apparatus includes electrical coil means formed of multiple turns of enamel-covered electrical wire axially mounted on a core of magnetic material in electromagnetic energy coupling relationship therewith, and a relatively flat flexible electrical cable containing a plurality of spaced parallel conductors extending between the cable ends contains a loop shaped portion extending about an axis of said core over an arcuate distance greater than 180 degrees.