US 3781741 A
A transformer assembly having a plurality of annular shaped coil chambers and adapted to receive ferromagnetic laminations and coils has a pair of insulating caps each of which includes a plurality of integrally-formed annular ribs. The annular ribs are disposed concentrically on and perpendicular to the front wall of each of the caps so as to define a plurality of concentric hollow coil chambers. Each of the chambers has a substantially rectangular cross-section. A plurality of coil sleeves is provided each having a different cross section so as to correspond with each of the ribs. Each of the coil sleeves includes end flanges and a shoulder complementary with the respective rib. The front wall of at least one cap contains apertures as directed to the connecting flange side of the respective coil chamber. The connecting flange side bears overlapping teeth. Electrical connection means are disposed along the outside portion of each of the caps providing a means for electrical connection to the coil windings. The ribs are placed so as to seat along the shoulders of the sleeves thereby defining a plurality of closed coil chambers and included in a coil space devoid of any ribs.
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Description (OCR text may contain errors)
United States Patent [1 1 Weiner [4 1 Dec. 25, 1973 TRANSFORMER ASSEMBLY  Inventor: Norbert Weiner, Pernze 5275,
Bergneustadt, Germany  Filed: June 18, 1973  Appl. No.: 370,871
 Foreign Application Priority Data Primary Examiner-Thomas J. Kozma I Attorney-Allison C. Collard  ABSTRACT A transformer assembly having a plurality of annular shaped coil chambers and adapted to receive ferromagnetic laminations and coils has a pair of insulating caps each of which includes a plurality of integrallyformed annular ribs. The annular ribs are disposed concentrically on and perpendicular to the front wall of each of the caps so as to define a plurality of concentric hollow coil chambers. Each of the chambers has a substantially rectangular cross-section. A plurality of coil sleeves is provided each having a different cross section so as to correspond with each of the ribs. Each of the coil sleeves includes end flanges and a shoulder complementary with the respective rib. The front wall of at least one cap contains apertures as directed to the connecting flange side of the respective coil chamber. The connecting flange side bears overlapping teeth. Electrical connection means are disposed along the outside portion of each of the caps providing a means for electrical connection to the coil windings. The ribs are placed so as to seat along the shoulders of the sleeves thereby defining a plurality of closed coil chambers and included in a coil space devoid of any ribs.
10 Claims, 6 Drawing Figures TRANSFORMER ASSEMBLY This invention relates to a coil or transformer body for a cylinder type assembly. The coil body has a plurality of annular shaped coil chambers which are superimposed vertically with respect to the annular cylindrical axis. The coil chambers essentially comprise bushing or sleeve portions having end flanges, two insulating caps, having a front wall and a slip-on bushing. The slip-on bushing of each cap slips over a'front flange of the coil or winding sleeves while the engaging front edges slip over each other in a folded manner.
It has been found that coils that are made in a cylinder type assembly have a lesser leakage than coils made in a disc type assembly. Cylindrically formed coils have been found to be better suited for the higher audio frequencies.
However, such coil or transformer bodies, in particular, bodies having rather small dimensions will not always meet the standards set forth by the Society of German Electrical Engineers and in particular standard [I VDE 0551. A transformer body of the above type is disclosed in German laid open patent 1,932,174, dated .lan. 14, 1971. However, the body disclosed has relative broad flanges that are required at the coil chambers, whereby coil chamber space is lost. This leads to undesirable losses and to increased requirements for space.
It is therefore, an object of the present invention to provide a transformer body which meets the aforementioned standards and which more efficiently utilize coil chamber space.
Accordingly the objects of the present invention are obtained by providing an annular rib on the inner wall of the front wall of each insulating cap for each coil chamber. The annular rib has about half of the wall thickness of the sleeve portion. Each coil chamber is provided with a front face shoulder at the inner face of the sleeve portion and has half of the wall thickness of the sleeve portion andextends in direction of the angular axis equal to the length of the annular rib. The annular rib fills out the cross section of said front face shoulder of the sleeve portion of the respective coil chamber so that the inner surface of said rib is flushed with the inner surface of the sleeve portion.
This arrangement provides that the insulation path is essentially the same length as the aforementioned annular rib. This annular rib can be so arranged that the required insulation path is provided, in particular, in smaller coil bodies.
The insulation path should be so long as is requested by competent authorities. The transformer body permits voltages in excess of 18,000 volts. The flanges of the coil chambers may be as thin as desired. It is only necessary they act effectively under the desired voltage level. Therefore, each coil chamber can be wound about the total axial length thereby utilizing a large portion of the transformers body in the winding. Each transformer body may be dimensioned for the desired output. It is very important to keep leakage as low as possible. It is also important that the inventive transformer body meet all the requirements of the aforementioned standards. This is particularly important when small transformer bodies are involved, so that the inventive body may be used, for example, as audio frequency transformers, and output transformers of auxilliary loud speakers in radios and televisions.
In a preferred embodiment of the invention the front portion of the bushing of one of the insulating caps is displaced by the amount of the wall thickness and is increased by the length of the insulating path. In this way, the insulating caps may be provided with relatively thin walls.
In accordance with a further embodiment of the invention an opening is provided in the front wall of each insulating cap on the side of the connecting flange of each coil chamber. The coil wires can be easily mounted and provide the means for connecting wires to adjoining or adjacent contact pins yet still maintain the desired insulation path.
In a further embodiment in accordance with the invention, an insulating plate is provided beneath each opening at the inner side of the corresponding insulating cap. The insulating plate extends outwardly and vertically with respect to the front wall face. This insulating plate provides a sufficient insulation with respect to the core plates.
In still a further embodiment of the invention, an opening is provided in one insulating cap for the inner coil chamber and an opening in the other insulating cap for the outer coil chamber. This arrangement is particularly advantageous for a horizontal connection of the transformer.
In still a further embodiment of the invention, an opening for the outer coil chamber and, an opening for the inner coil chamber are provided at the front wall of one of the insulating caps. This arrangement of the openings in one front face permits extension of the coil wires through only one front wall and thereby increase the protective insulation of the coil body. This arrangement permits a vertical connection of the transformer body.
Other objects and features of the present invention will become apparent from the following detailed description when taken in connection with the appended drawings to which reference should be made. It is to be understood, however, that the drawings are designed for the purpose of illustration only and are not intended as a definition of the limits and scope of the invention.
In the drawings, wherein similar reference numerals denote similar elements throughout the several views:
FIG. 1 is a partial cross section view ofa coil body for horizontal connection showing the core plates inserted;
FIG. 2 is a side view according to FIG. 1 but without core plates;
FIG. 3 is a plan view partly in section according to FIG. 1;
FIG. 4 is a view ofa coil body for vertical connection partially cut and showing the core plates inserted;
FIG. 5 is a view according to FIG. 4 taken in the direction of arrow V; and
FIG. 6 is a plan view according to FIG. 4 also partially cut.
Referring now to the figures, there is shown a transformer body having two coil chambers in a substantially rectangular cross section. One inner coil chamber 1 is provided with a bushing or sleeve portion 2 as well as two end flanges 3 and 4. Openings 5 for the coil wires or windings are provided in connecting flange side 4' of coil chamber 1. The required wall thickness of coil chamber 1 is designed in accordance with the mechanical as well a the dielectric strength of the employed material. A shoulder 6 is provided on the front face of the inner face of the sleeve portion. The width of the shoulder corresponds to about half ofthe wall thickness of the coil chamber and the lengths in direction of the chamber axis correspond to the desired path of insulation.
A further coil chamber 7 encompasses coil chamber 1 in radial direction, whereby the coil chamber 7 is constructed in the same manner as the coil chamber 1.
Thus, the same numeral references may be used for both chambers. However, the connecting flange side 4' of coil chamber 7 which contains the openings for the coil wires are opposite to the flange 4 of coil chamber 1. The coil windings are not shown in the drawing.
Two insulating caps 8 and 9 are slipped over the coil chambers 1 and 7. Insulating cap 8 is provided with a front wall 10 as well as integrally-formed bushing 11 which extends over a portion of the axial length of the coil chambers. An opening 12 is provided in front wall 10 of insulating cap 8 which is directed to the connecting face of flange side 4 of the inner coil chamber 1. Two annular ribs 13 are provided at'the front wall 10 for each of'the coil chambers l and 7, respectively.
These annular ribs 13 run in the axial direction of the coil chamber and encompassa cross section which is equal to the inner cross section of the corresponding coil chamber,.The wall thickness of each annular rib 13 is equal to half of the wall thickness of coil chambers 1 and 7, respectively. The length of each annular rib 13 in the axial direction of the coil chambers is equal to the lengths of shoulders 6. Therefore, the annular ribs 13 completely fill out the shoulders 6 (seen in FIGS. 1 and 3). The annular ribs 13 are flush with the inner face of bushing portions 2, so that the inner space of the sleeve portions is not restricted and may be completely used for winding the inner coil chamber, or for the core plates or laminations 14. Insulating cap 8 carries an in sulating plate 15 which is mounted below opening 12. This insulating plate 15 may be provided with an angular shank 16, seen in FIG. 1. Insulating plate l5receives the connecting elements 17 that might comprise soldered terminals, clamp terminals or connecting pins.
Insulating cap 9'is essentially the same as insulating cap 8. However, at the front face of slip-on bushing 11 is mounted an annular front ring 18 that is displaced to the outside byv the amount of the wall thickness of the insulating cap. The axial length thereof is increased in accordance withthe desired insulating path. Hence, insulating cap 9 may be telescopically slipped over insulating cap 8. Insulating cap 9 is provided with an opening 12 in front wall 10, whereby the opening is directed to the connecting flange 4 of outer coil chamber 7. Opening 12' is opposite opening 12 when viewed in axial direction of the coil chambers.
As can be seen from FIGS. 1 and 3, the total coil space of each coil chamber 1 and 7 can be totally used. At no place has there been the requirement that the coil chamber be reduced in size. Annular ribs 13 and front face ring 18 provide a sufficient insulating path for the coils as well as for the core plates. This coil body is designed for a horizontal connection as in a switch board.
Referring to FIGS. 4 and 6 a coil body is shown adapted for use in the vertical position on a switch board. Coil chambers 1 and 7 are essentially the same in their construction as the coil chambers described above. The same is true for the insulating caps 8 and 9. However, in opposite portion 10' of the front wall 10, insulating cap 9 is provided with an opening 12 for the inner coil chamber 1 and an opening 12' forthe outer coil chamber 7. The connecting flange sides 4' which are directed to openings 12 and 12 are provided with corresponding openings '5 for the coil wires. Each connecting flange side 4"bears several groups 20 of ridgelike overlapping teeth 21 between which the ends of coil wire can be clamped. Insulating plates 15 are mounted in the inner portion of the insulating cap 9 beneath openings 12 and 12 so that the insulating plates extend outwardly from the front wall. An outer rib 18 which is mounted on portions 10 is provided with connecting pins 17. Lateral ribs or flanges 19 support outer rib 18, so that the connecting pins 17 are securely held. The connecting pins are provided with receiving elements' for the metallic plug parts. Consequently, the inventive coil body permits protective insulation of the coil body when vertically mounted. The teeth 21 are very advantageous forthe winding of the coil since the ends of the coil wire can be clamped without difficulties. After the insulating caps 8 and 9 are slipped over the coil chambers the ends of the coil wires are detached from the teeth 21 and connected with the respective connecting pins 17.
While only several embodiments of the present invention have been shown and described, it will be obvious to those persons of ordinary skill in the art that many changesand modifications may be made thereunto without departing from the spirit and scope of the invention.
What is claimed is: 1. A coil body assembly having a plurality of annular shaped coilchambers and adapted to receive ferromagnetic-laminations and coils comprising:
' a pair of insulating caps each of which includes a plurality of integrally formed annular ribs, said ribs disposed concentrically on and perpendicular to the front wall of each of said caps so as to define a plurality of concentric hollow'coil chambers each of the chambers having a substantially rectangular cross section; a plurality of coil sleeves each having a different cross section so as to be corresponding with each of said ribs, each of. said sleeves including end flanges and shoulders complementary with said ribs; and I i electrical connection means disposed along the outside portion of at least one of said caps providing a means for electrical connection to the coil windings, said cap ribs being placed so as to seat along the shoulders and thereby define a plurality of closed coil chambers and an included inner coil space devoid of said ribs.
2. The coil body as in claim 1 wherein the thickness of said ribs and the sleeve shoulders are approximately half the thickness of said coil sleeve so that each of said ribs mate with said complementary coil sleeve without discontinuity of cross section.
3. The coil body asin claim 2 further including an insulating plate disposed substantially perpendicular to and placed on each of said insulating caps, and plates oppositely directed from said plurality of said ribs so as to receive and confine the ferromagnetic laminations.
4. The coil body as in claim 3 wherein said electrical connection means includes a plurality of conductive equal number of said pins disposed on each one of said insulating cap plates.
5. The coil body as in claim 2 wherein one of the insulating caps further includes a pair of parallel spacedapart insulating plates for receiving and confining the ferromagnetic laminations therebetween, said plates disposed perpendicular to said insulating cap and oppositely directed from said ribs.
6. The coil body as in claim 5 wherein said electrical connection means comprises a plurality of outer flanges disposed on the outer rim of one cap and in parallel alignment to of said insulating plates, and wherein said electrical connection means includes electrical connection pins disposed in and supported by said flanges, said pins being disposed substantially parallel to said insulating plates.
7. The coil body as in claim 6 wherein said insulating cap containing said insulating plates further includes a plurality of apertures provided therethrough allowing access to each of the coil chambers.
8. The coil body as in claim 4 wherein said insulating cap includes a plurality of apertures providing access to each of the coil chambers.
9. The coil body as in claim 2 wherein one of said insulating caps includes an integrally formed insulating end ring disposed on bushing portion, said insulating end ring flaring slightly outwardly so as to partially cover said complimentary bushing portion of said other insulating cap.
10. The coil body as in claim 7 wherein said coil sleeve bears on one side of one end flange teeth disposed perpendicular to said flange and extending through the apertures.