A method for producing a spiral-shaped body, in particular an electric coil, made of an electrically conductive material. First, the material is wound about a mandrel in a casting mold in order to form a coil with a plurality of windings, and pressure is then exerted onto the coil in the axial direction of the coil. The pressure leads to a deformation and compression of the cross-section of the individual windings in the axial direction of the coil. By compressing the coil, an optimal use of space is achieved with an electric coil, for example for an electric machine.

Methods and apparatus for producing helix windings used for a transformer are provided. For example, apparatus comprise an electrically conductive mandrel comprising an elongated body, a head comprising an eyelet detail, and a winding structure disposed along the elongated body.

Methods and apparatus for producing helix windings used for a transformer are provided. For example, apparatus comprise an electrically conductive mandrel comprising an elongated body, a head comprising an eyelet detail, and a winding structure disposed along the elongated body.

An apparatus for creating an electromagnetic coil, including: a platform for building the coil; a dispenser to dispense a wire via a nozzle; a wire feeder to feed the wire through the dispenser; a coating applicator to apply a bondable overcoat to the wire, such that when a section of the wire is laid adjacent to another section of the wire, the bondable overcoats of the respective sections bond to each other; one or more actuators to provide at least three degrees of freedom to the dispenser and/or the platform; and a processor to control the one or more actuators to move the dispenser and/or platform such that the wire is dispensed at a specified location relative to the platform; wherein the processor controls the one or more actuators based on a program stored in a memory, the program including instructions for laying the wire according to a predetermined pattern.

An apparatus for creating an electromagnetic coil, including: a platform for building the coil; a dispenser to dispense a wire via a nozzle; a wire feeder to feed the wire through the dispenser; a coating applicator to apply a bondable overcoat to the wire, such that when a section of the wire is laid adjacent to another section of the wire, the bondable overcoats of the respective sections bond to each other; one or more actuators to provide at least three degrees of freedom to the dispenser and/or the platform; and a processor to control the one or more actuators to move the dispenser and/or platform such that the wire is dispensed at a specified location relative to the platform; wherein the processor controls the one or more actuators based on a program stored in a memory, the program including instructions for laying the wire according to a predetermined pattern.

A bobbin wound coil for an electromagnetic coupling includes a bobbin having a cylindrical body, end flanges disposed at opposite ends of the body and a terminal connector on an exterior side of one of the end flanges. A coil has a beginning portion extending through first openings in the terminal connector and an end flange and an end portion extending through second openings in the terminal connector an end flange. The second openings in the terminal connector and end flange are forward and rearward, respectively, of the corresponding first openings in a circumferential direction. A section of the beginning portion extends between the first openings in the terminal connector and end flange and a section of the end portion extends between the second openings in the terminal connector and end flange such that section of the end portion crosses over the section of the beginning portion.

A bobbin wound coil for an electromagnetic coupling includes a bobbin having a cylindrical body disposed about a central axis, end flanges disposed at each axial end of the body and a terminal connector on an exterior side of one of the end flanges. The terminal connector includes a body defining a central cavity and a post extending from an exterior surface of the body of the terminal connector. A coil includes a beginning portion extending through the body of the terminal connector and the end flange on which the terminal connector is located, an end portion extending through the body of the terminal connector and the end flange, and a center portion extending between the beginning portion and the end portion and wound about the cylindrical body of the bobbin. One of the beginning portion and the end portion of the coil is wound about the post.

A bobbin wound coil for an electromagnetic coupling includes a bobbin having a cylindrical body, end flanges disposed at opposite ends of the body and a terminal connector defining a central cavity bordered, in part, by inner and outer walls and a side wall extending between the inner and outer walls. A coil has a beginning portion extending through first openings in the inner and outer walls, an end portion extending through second openings in the inner and outer walls, and a center portion wound about the bobbin body. The first and second openings in the inner wall divide the inner wall into first and second circumferential end sections and a center section. A portion of one of the circumferential end sections and the center section is spaced from the side wall to define a recess configured to receive one of the beginning and end portions of the coil.

A bobbin wound coil for an electromagnetic coupling includes a bobbin having a cylindrical body, end flanges disposed at opposite ends of the body and a terminal connector defining a central cavity bordered, in part, by inner and outer walls and a side wall extending between the inner and outer walls. A coil has a beginning portion extending through first openings in the inner and outer walls, an end portion extending through second openings in the inner and outer walls, and a center portion wound about the bobbin body. The first and second openings in the inner wall divide the inner wall into first and second circumferential end sections and a center section. A portion of one of the circumferential end sections and the center section is spaced from the side wall to define a recess configured to receive one of the beginning and end portions of the coil.

Methods and apparatus for producing helix windings used for a transformer are provided. For example, apparatus comprise an electrically conductive mandrill comprising an elongated body, a head comprising an eyelet detail, and a winding structure disposed along the elongated body.