Abstract
A winding is provided, which comprises a form element having a longitudinal axis defining a longitudinal direction and a radial direction perpendicular to the longitudinal axis. The form element comprises a core with a lateral surface, and adjustable elements arranged on the lateral surface of the core. The adjustable elements are elongated and extend along the longitudinal direction. A thickness of the adjustable elements in a radial direction is altered along the longitudinal direction. A conductor is wound around the form element along the longitudinal direction forming turns of the winding.
Claims
1. A winding, comprising, a form element having a longitudinal axis defining a longitudinal direction and a radial direction perpendicular to the longitudinal axis, the form element comprising: a core with a lateral surface, and adjustable elements arranged on the lateral surface of the core, wherein the adjustable elements are elongated and extend along the longitudinal direction, wherein the adjustable elements comprise stacked layers, wherein a thickness of the adjustable elements in a radial direction is altered along the longitudinal direction, and wherein the thickness of the adjustable elements in a radial direction is altered by at least one removed or added layer along the longitudinal direction, and a conductor wherein the conductor is wound around the form element along the longitudinal direction forming turns of the winding.
2. The winding according to claim 1, wherein the cross section of the form element perpendicular to the longitudinal axis is symmetrical to a central point of the cross section.
3. The winding according to claim 1, wherein the adjustable elements are arranged uniformly on the lateral surface of the core.
4. The winding according to claim 1, wherein 12, 16, 24 or 36 adjustable elements are arranged on the lateral surface of the core.
5. The winding according to claim 1, wherein the thickness of the adjustable elements in a radial direction alters gradually along the longitudinal direction.
6. The winding according to claim 1, wherein the thickness of the adjustable elements in a radial direction varies by an amount of 0.1 mm to 10 mm along the longitudinal direction.
7. The winding according to claim 1, wherein the layers comprise a first type of layer and a second type of layer, wherein the first type of layer has a greater thickness than the second type of layer, and wherein the thickness of the adjustable element is altered along the longitudinal direction by either a removed at least one second type of layer, or by an added least one second type of layer.
8. The winding according to claim 7, wherein at least one second type of layer is arranged on the core in a radial direction and one first type of layer is stacked on the at least one first type of layer, and wherein the thickness of the adjustable element is altered along the longitudinal direction by either a removed at least one second type of layer, or by an added least one second type of layer added in between the core and the at least one first type of layer.
9. The winding according to claim 8, wherein a further first type of layer is stacked on the one first type of layer in a radial direction, and wherein the thickness of the adjustable element is altered along the longitudinal direction by either a removed at least one second type of layer, or by an added at least one second type of layer added in between the core and the further first type of layer.
10. The winding according to claim 7, wherein one first type of layer is arranged on the core in a radial direction and at least one second type of layer is stacked on the at least one first type of layer, and a second first type of layer is stacked on the at least one second type of layer, and wherein the thickness of the adjustable element is altered along the longitudinal direction by either a removed at least one second type of layer, or by an added at least one second type of layer added in between the core and the second first type of layer.
11. The winding according to claim 7, wherein the first type of layers have a thickness of 3 mm to 10 mm.
12. The winding according to claim 1, wherein the layers are adhered to each other or the core at discrete spots along the longitudinal direction.
13. The winding according to claim 1, wherein the layers comprise materials based on cellulose fiber as paper, pressboard, cardboard, wooden strips, wooden sticks, batten or materials based on a polymer as DDP, epoxy or silicone.
14. The winding according to claim 1, wherein spacer elements are arranged in between the turns of the winding.
15. The winding according to claim 14, wherein the spacer elements are located above the adjustable elements in a radial direction.
Description
BRIEF DESCRIPTION OF FIGURES
[0027] The figures serve solely to illustrate the invention and are therefore only schematic and not drawn to scale. Some parts may be exaggerated or distorted in the dimensions. Therefore, neither absolute nor relative dimensions can be taken from the figures. Identical or identically acting parts are provided with the same reference numerals.
[0028] FIG. 1 shows a spatial representation of an embodiment of a winding;
[0029] FIG. 2 shows a cross section of a form element along a longitudinal direction with a sharp edge;
[0030] FIGS. 3A and 3B show cross sections of form elements along a radial direction comprising a core and adjustable elements;
[0031] FIG. 4B to 4C show cross sections of a winding along a longitudinal direction during the manufacturing process;
[0032] FIGS. 5A and 5B show cross sections of a another embodiment of the winding along a longitudinal direction before and after the manufacturing process;
[0033] FIG. 6 shows a cross section of a form element along a longitudinal direction; and
[0034] FIG. 7 shows a cross section of another embodiment of a form element along a longitudinal direction.
DETAILED DESCRIPTION
[0035] FIG. 1 shows a spatial representation of an embodiment of the winding 1. The winding 1 comprises a form element 2 having a longitudinal axis LA defining a longitudinal direction L and a radial direction R perpendicular to the longitudinal axis LA. The form element 2 consists of a core 3 and elongated adjustable elements 4 that are arranged on a lateral surface of the core 3 such that they extend along the longitudinal direction L. Here, the core 3 is cylindrical, but it is not limited to this and can have any other shape, e.g., rectangular. A conductor 5 having a rectangular profile is wound around the form element 2 along the longitudinal direction L forming turns 6 of the winding 1. Spacer elements 7 are arranged in between the turns 6 aligning in the longitudinal direction L, as illustrated in FIG. 1 I). Such an arrangement of the spacer elements 7 provides an excellent stability to the winding 1, as forces applying on the winding 1 in the longitudinal direction L do not generate any leverage, torque or lateral forces between the spacer elements 7 and the conductor 5.
[0036] The thickness of the adjustable elements 4 is altered along the longitudinal direction L in order to make up for the production tolerances of the conductor 5 and the core 3. In the embodiment shown in FIG. 1 the thickness of the adjustable elements 4 is altered gradually, as shown in FIG. 1 II). In this way a sharp edge on the surface of the adjustable element 4 facing the conductor 5 can be omitted which could harm the conductor 5, as shown in FIG. 2.
[0037] Due to the altered thickness of the adjustable elements, the turns 6 of the winding 1 can be shifted a bit in the radial direction R, as shown in FIG. 1 II). However, as far as the turns 6 overlap more than 95% along the longitudinal direction L, a high stability for the winding 1 is given. In FIG. 1 III) it can be seen that the conductor 5 is supported by the adjustable element 4 forming a gap between the core 3 and the conductor 5 besides the adjustable elements 4. The conductor 5 is wound around the form element 2 such that the spacer elements 7 are located above the adjustable elements 4.
[0038] FIG. 3A and FIG. 3B show cross sections of form elements 2 in the radial direction R. 12 adjustable elements 4 are arranged uniformly on the lateral surface of the form element 2 to distribute radial forces on the winding 1 evenly. Embodiments with 16, 24, 36 or even more adjustable elements 4 are appropriate, too. In the magnified view of the adjustable elements 4 it can be recognized that the adjustable elements 4 comprise stacked layers 8. A thicker first type of layer 8a is positioned outwards and a thinner second type of layer 8b is arranged in between the core 3 and the first type of layer 8a. The thickness of the adjustable element 4 is altered by removing the second type of layer 8b along the longitudinal direction L.
[0039] Exemplary, all the adjustable elements 4 comprise the first and second type of layer 8 in the beginning of the winding 1. Along the longitudinal direction L, the thickness of the adjustable element 4 is altered by removing second type of layers 8b from two adjustable elements 4 symmetrically on opposite sides of the core 3 as shown in FIG. 3A. Even further along the longitudinal direction L, additional second type of layers 8b can be removed to compensate for a stronger production deviations of the components, as shown in FIG. 3B.
[0040] FIG. 4A to 4C show cross sections of the winding 1 along the longitudinal direction L during the manufacturing process. The adjustable elements 4 have a similar structure as the adjustable elements 4 shown in FIG. 3, with one second type of layer 8b arranged one the core 3 and one first type of layer 8a stacked upon the second type of layer 8b. The layers 8 are adhered to each other and to the core 3 just at discrete spots S and not over the entire length, although the adhesive is distributed over a certain length in the beginning of the winding 1 to improve the cohesion of the layers 8. Thus, the removal of a layer 8 is simplified. In FIG. 4B the removal of the second type of layer 8b along the longitudinal direction L is shown. The covering first type of layer 8a is detached from the second type of layer 8b and bend outwardly. Next, the second type of layer 8b is cut in two, detached from the core 3 and removed from the form element 2. Here, just the removal of the second type of layer 8b is presented, but nevertheless the thickness of the adjustable element 4 also can be increased by adding one or more second type of layer 8b in between the core 3 and the first type of layer 8a.
[0041] As can be seen in FIG. 4C the first type of layer 8a adapts to the underlying surface and alters gradually along the longitudinal direction L. In this way a sharp edge on the surface of the adjustable element 4 is bypassed, which could damage the conductor 5 or and insulation, as shown in FIG. 2. Hence, it is desired that the layers 8 exhibit a certain degree of flexibility, which can be provided by using suitable materials and thicknesses for the layers 8. Suitable materials could for example be based on cellulose fiber as paper, pressboard, cardboard, wooden strips, wooden sticks or batten, but also materials based on a polymer as e.g., DDP, epoxy or silicone are applicable. For these materials thicknesses of 3 mm to 10 mm for the first type of layer 8a and 0.1 mm to 0.5 mm for the second type of layer 8b are reasonable to compromise between the required properties for the form element 2. For instance, the first type of layer 8a can be a wooden stick with a thickness of 4 mm and the second type of layer 8b a cardboard with a thickness of 0.2 mm.
[0042] In the embodiment shown in FIGS. 5A and 5B, a further second type of layer 8b is arranged and adhered onto the layer 8 structure of the embodiment shown in FIG. 4A. The thickness of this adjustable element 4 can be reduced by removing the second type of layer 8b, in a similar way as shown in FIG. 4. In order to increase the thickness of the adjustable element 4 an additional second type of layer 8b is added, as shown in FIG. 5A. For adding the second type of layer 8b, the further first type of layer 8a is bent and the second type of layer 8b is disposed on and glued to the underlying first type of layer 8a and the further second type of layer 8b.
[0043] FIG. 6 shows an embodiment of the adjustable element 4, wherein three second type of layers 8b are arranged on top of each other in between the core 3 and the first type of layer 8a. Hence, the amount of the possible reduction in thickness is larger compared to the embodiment shown in FIG. 4 and FIG. 5. The three second type of layers 8b have the same thickness here but could also have different thicknesses. If second type of layers 8b with different thicknesses are employed, a layer 8 with a matching thickness to the desired amount of thickness reduction of the adjustable element 4 can be removed. In this way the manufacturing process can be accelerated, as it is not necessary to remove multiple thinner second type of layers 8b in several steps. As a matter of course the number of stacked second type of layer 8b is not limited to three.
[0044] The adjustable element 4 shown in FIG. 7 consists of two stacked second type of layers 8b sandwiched between two first type of layers 8a. The first type of layer 8a arranged on the core 3 forms a stable socket for the second type of layers 8b, and the covering first type of layer 8a fixes the second type of layer 8b by clamping them. The thickness of this adjustable element 4 is altered either by removing or adding a second type of layer 8b in between the first type of layers 8a.
[0045] It has to be noticed that the present disclosure is not limited to the layouts described before and that further layouts can be retrieved by combination of features taken from different figures and embodiments.
LIST OF USED REFERENCE SYMBOLS
[0046] 1 Winding [0047] 2 Form element [0048] 3 Core [0049] 4 Adjustable elements [0050] 5 Conductor [0051] 6 Turn [0052] 7 Spacer element [0053] 8 Layer [0054] 8a First type of layer [0055] 8b Second type of layer [0056] LA Longitudinal axis [0057] L Longitudinal direction [0058] R Radial direction [0059] S Spots of adhesion
