Bobbin wound coil for electromagnetic coupling machine

Abstract

A bobbin wound coil for an electromagnetic coupler includes a bobbin having a cylindrical body disposed about a central axis, end flanges disposed at axial ends of the cylindrical body and extending radially outward therefrom and defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, respectively, and a terminal connector on the outer side of one of the end flanges. In various embodiments, one or more of the cylindrical body, end flanges and / or terminal connectors are configured to avoid the need for an external ridge on the end flanges normally required to facilitate winding the coil, allow for the evacuation of fluids from a pocket formed on the outer side of the end flange, provide a means for tensioning and / or securing the ends of the coil during winding, and / or prevent rotation of the bobbin relative to the field shell of the coupler.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims the benefit of and priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 63 / 338,058, filed May 4, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to electromagnetic couplers. More particularly, the present invention relates to an improved bobbin wound coil for an electromagnetic coupler. [Background technology]

[0003] A conventional electromagnetic coupling machine includes an armature, and a force is applied to the armature to move the armature between an engaged position and a disengaged position with the rotor or friction disk to transmit a rotation or braking torque between one body coupled to the armature and another body coupled to the rotor or friction disk. The armature moves to at least one of the engaged and disengaged positions by an electromagnetic force generated when an electromagnet disposed on one side of the armature is energized to create an electromagnetic circuit between the electromagnet and the armature, drawing the armature toward the electromagnet and toward or away from the rotor or friction disk. The electromagnet includes a field shell made of a material having a relatively low magnetic reluctance, and a conductor to which an electric current is provided to energize the electromagnet and create an electromagnetic circuit by causing a magnetic flux to flow in and between the field shell and the armature. The conductor typically includes a coil wound around a bobbin mounted on or in the field shell and connected to an external power source.

[0004] Conventional bobbin wound coils have one or more drawbacks. Conventional bobbins include a cylindrical body, flanges extending radially outward from each end of the body and defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, and a terminal connector formed on the outer side of one of the end flanges and near the radial outer edge of the end flange. When a coil is wound onto a bobbin, a beginning portion of the coil typically passes through the terminal connector, passes through the end flange near the radial outer edge of the end flange, and then travels radially inward along the end flange onto the cylindrical body of the bobbin. The coil is then repeatedly wound around the cylindrical body, and finally, a terminal portion of the coil again passes through the end flange and the terminal connector near the radial outer edge of the end flange. As the coil is wound around the body of the bobbin, the coil must pass over a section extending radially inward of the beginning portion of the coil, and to accommodate this winding pattern, an outwardly projecting ridge is often formed on the outer side of one of the flanges, which creates manufacturing and packaging problems. Conventional bobbins often do not have adequate mechanisms and / or require additional mechanisms to properly tension the beginning and end portions of the coil during winding and / or secure the beginning and end portions of the coil within the terminal connector during winding. In some conventional bobbins, one or more of the flanges on the bobbin may be formed with recesses on the exterior side of the flange to balance the goals of strengthening the end flange while reducing weight and material. However, depending on the application and operating environment of the electromagnetic clutch, these recesses may collect fluids and debris. Finally, some conventional bobbins (and the coils attached thereto) are also subject to rotation relative to the field shell to which the bobbin is attached as a result of torque transmission during operation of the coupling machine. Summary of the Invention [Problem to be solved by the invention]

[0005] The inventors herein have recognized a need for a bobbin wound coil for an electromagnetic coupler that minimizes and / or eliminates one or more of the above-identified shortcomings. [Means for solving the problem]

[0006] The present invention relates to electromagnetic couplers. More particularly, the present invention relates to an improved bobbin wound coil for an electromagnetic coupler.

[0007] A bobbin wound coil for an electromagnetic coupler according to one embodiment includes a bobbin including a cylinder disposed about a central axis. The bobbin further includes a first end flange disposed at a first axial end of the cylinder and extending radially outward therefrom, the first end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder, and a second end flange disposed at a second axial end of the cylinder and extending radially outward therefrom, the second end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder. The bobbin further includes a terminal connector on the outer side of the first end flange. The bobbin wound coil further includes a coil having a beginning portion extending through a first opening in the terminal connector and the first opening in the first end flange, and a terminal portion extending through a second opening in the terminal connector and the second opening in the first end flange. The second opening in the terminal connector is in front of the first opening in the terminal connector in a first circumferential direction. The second opening in the first end flange is behind the first opening in the first end flange in the first circumferential direction. The starting portion includes a first section extending from the first opening in the terminal connector to the first opening in the first end flange, and the ending portion includes a first section extending from the second opening in the terminal connector to the second opening in the first end flange. The first section of the ending portion of the coil extends beyond the first section of the starting portion of the coil.

[0008] A bobbin wound coil for an electromagnetic coupler according to another embodiment includes a bobbin including a cylindrical body disposed about a central axis. The bobbin further includes a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, and a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin further includes a terminal connector on the outer side of the first end flange. The terminal connector includes a body defining a central cavity and includes axially spaced inner and outer walls, first and second circumferentially spaced side walls extending between the inner and outer walls, and a radially inner side wall extending between the inner and outer walls. The coil includes a starting portion extending through a first opening in each of the inner and outer walls of the terminal connector body, a terminal portion extending through a second opening in each of the inner and outer walls of the terminal connector body, and a central portion extending between the starting and terminal portions and wound around the cylinder. The inner wall of the terminal connector body includes first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by corresponding ones of the first and second openings in the inner wall. The first circumferential end section, the second circumferential end section and a portion of one of the central sections define a first recess away from the radially inner sidewall configured to receive one of the starting and terminal portions of the coil.

[0009] A bobbin wound coil for an electromagnetic coupler according to another embodiment includes a bobbin including a cylindrical body disposed about a central axis. The bobbin further includes a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, and a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin further includes a terminal connector on the outer side of the first end flange. The terminal connector includes a body defining a central cavity and a post extending from an outer surface of the body of the terminal connector. The bobbin further includes a coil having a starting portion extending through the body and the first end flange of the terminal connector, a terminal portion extending through the body and the first end flange of the terminal connector, and a central portion extending between the starting portion and the terminal portion and wound around the cylindrical body of the bobbin, One of the starting portion and the terminal portion of the coil is wound around the post.

[0010] A bobbin wound coil for an electromagnetic coupler according to one embodiment includes a bobbin including a cylinder disposed about a central axis. The bobbin further includes a first end flange disposed at a first axial end of the cylinder and extending radially outward therefrom, the first end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder, and a second end flange disposed at a second axial end of the cylinder and extending radially outward therefrom, the second end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder. An axial thickness of the first end flange varies adjacent a radial inner wall, a radial outer wall, and first and second side walls extending radially between the radial inner wall and the radial outer wall to define a recess on the outer side of the first end flange. The radial outer wall includes an opening extending therethrough and in communication with the recess.

[0011] A bobbin wound coil for an electromagnetic coupler according to another embodiment includes a bobbin including a cylinder disposed about a central axis. The bobbin further includes a first end flange disposed at a first axial end of the cylinder and extending radially outward therefrom, the first end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder, and a second end flange disposed at a second axial end of the cylinder and extending radially outward therefrom, the second end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder. The bobbin further includes a rotation stop member extending from one of the cylinder, the first end flange, and the second end flange and configured to engage a field shell of the electromagnetic coupler.

[0012] A bobbin wound coil for an electromagnetic coupler according to another embodiment includes a bobbin including a cylinder disposed about a central axis, the bobbin further including a first end flange disposed at a first axial end of the cylinder and extending radially outward therefrom, the first end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder, and a second end flange disposed at a second axial end of the cylinder and extending radially outward therefrom, the second end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder, the bobbin further including means for preventing rotation of the bobbin relative to a field shell of the electromagnetic coupler.

[0013] A method of forming a bobbin wound coil for an electromagnetic coupler according to one embodiment includes providing a bobbin including a cylindrical body disposed about a central axis. The bobbin further includes a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin further includes a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin further includes a terminal connector on the outer side of the first end flange. The method further includes inserting a starting portion of the coil through a first opening in the terminal connector and a first opening in the first end flange, winding the coil around the cylindrical body, and inserting an end portion of the coil through a second opening in the first end flange behind the first opening in the first end flange in the first circumferential direction and a second opening in the terminal connector in front of the first opening in the terminal connector in the first circumferential direction such that a first section of the end portion of the coil extending from the second opening in the first end flange to the second opening in the terminal connector exceeds a first section of the start portion of the coil extending from the first opening in the terminal connector to the first opening in the first end flange.

[0014] A method of forming a bobbin wound coil for an electromagnetic coupler according to another embodiment includes providing a bobbin including a cylindrical body disposed about a central axis, a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, and a terminal connector on the outer side of the first end flange. The terminal connector includes a body defining a central cavity and includes axially spaced inner and outer walls, first and second circumferentially spaced sidewalls extending between the inner and outer walls, and a radially inner sidewall extending between the inner and outer walls. The inner wall of the body of the terminal connector includes first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by first and second openings in the inner wall. The first circumferential end section, the second circumferential end section and a portion of the central section are spaced from the radially inner sidewall to define a first recess. The method further includes inserting a beginning portion of a coil through the first opening in the inner wall of the terminal connector, winding the coil about the cylindrical body, and inserting a terminal portion of the coil through a second opening in the inner wall of the terminal connector, where one of the beginning and ending portions of the coil extends through the first recess.

[0015] A method of forming a bobbin wound coil for an electromagnetic coupler according to another embodiment includes providing a bobbin including a cylinder disposed about a central axis, a first end flange disposed at a first axial end of the cylinder and extending radially outward therefrom, the first end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder, a second end flange disposed at a second axial end of the cylinder and extending radially outward therefrom, the second end flange defining an inner side facing the cylinder and an outer side facing away from the cylinder, and a terminal connector on the outer side of the first end flange. The terminal connector includes a body defining a central cavity and a first extending from an outer surface of the body of the terminal connector. The method further includes inserting a start portion of the coil through the terminal connector and the first end flange, winding the coil around the cylinder, and inserting a end portion of the coil through the first end flange and the terminal connector. The method further includes winding one of the start portion and the end portion of the coil around a post.

[0016] The bobbin wound coil according to the teachings herein represents an improvement over conventional bobbin wound coils used in electromagnetic couplers. In particular, the coil of the bobbin wound coil is wound in a configuration that eliminates any need for an outwardly protruding ridge on the exterior side of the end flange to accommodate typical wiring patterns, thereby improving manufacturing and packaging.

[0017] These and other aspects, features, details, utilities and advantages of the present invention will become apparent from a reading of the following description and claims, and from a review of the accompanying drawings.

[0018]

[0019]

[0020]

[0021]

[0022]

[0023] [Brief description of the drawings]

[0024] [Figure 1] 1 is a cross-sectional view of an embodiment of an electromagnetic coupler that may include a coil wound on a bobbin in accordance with the teachings herein. [Diagram 2] FIG. 2 is a perspective view of one embodiment of a coil wound on a bobbin in accordance with the teachings herein. [Diagram 3] FIG. 2 is a perspective view of one embodiment of a coil wound on a bobbin in accordance with the teachings herein. [Figure 4] FIG. 2 is a perspective view of one embodiment of a coil wound on a bobbin in accordance with the teachings herein. [Diagram 5] FIG. 13 is a perspective view of another embodiment of a coil wound on a bobbin in accordance with the teachings herein. [Figure 6] FIG. 5 is another perspective view of the coil wound on the bobbin of FIGS. 2 to 4. [Figure 7] FIG. 7 is an enlarged perspective view of a portion of the coil wound around the bobbin in FIGS. 2 to 4 and 6. [Figure 8] FIG. 13 is a perspective view of another embodiment of a coil wound on a bobbin in accordance with the teachings herein. [Figure 9] FIG. 7 is an enlarged perspective view of a portion of the coil wound around the bobbin in FIGS. 2 to 4 and 6. [Figure 10] FIG. 7 is an enlarged perspective view of a portion of the coil wound around the bobbin in FIGS. 2 to 4 and 6. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Referring now to the drawings, in which like reference numbers are used to identify identical components in the various figures, FIG. 1 shows an electromagnetic coupling device 10 including a coil wound on a bobbin. In the illustrated embodiment, the coupling device 10 provides a braking torque to a rotating body, such as a shaft, gear, pulley, blade, etc., to slow or stop the rotation of the rotating body. It will be understood by those skilled in the art that the device 10 may be used in a wide variety of industrial and other applications requiring a brake. Although the coupling device 10 functions as a brake in the illustrated embodiment, it should be understood that the coil wound bobbin embodiments disclosed herein may be used in electromagnetic coupling devices configured to function as a clutch to transfer torque from a rotating body to a rotatable body. The device 10 may include a rotor 12, a brake plate 14, an armature 16, a spring 18, a spacer 20, and an electromagnet 22.

[0026] The rotor 12 is provided to transmit the brake torque to a shaft or other rotating body. The rotor 12 may be made of conventional metal or plastic and may be made by stamping, molding and / or machining. The rotor 12 may be annular in shape and disposed about and centered on an axis of rotation 24. The rotor 12 is coupled to a shaft (not shown) and configured to rotate therewith about the axis 24, and may be rotatably coupled to the shaft in a variety of ways that allow for axial movement of the rotor 12 relative to the shaft to allow proper operation of the device 10 while accounting for wear, vibration, runout or thermal expansion. For example, the radially inner surface of the rotor 12 and the radially outer surface of the shaft may have complementary torque-transmitting shapes, such as splines (as shown in the illustrated embodiment), keys and keyways, single or double D-shaped or hexagonal. The rotor 12 includes friction surfaces on both sides 26, 28 that are configured to engage the brake plate 14 and the armature 16, respectively, during application or engagement of the brake.

[0027] The brake plate 14 is configured to engage the rotor 12 during application of the brake to transfer a braking torque to the rotor 12. The brake plate 14 provides a reaction surface against which the armature 16 presses against the rotor 12 during application of the brake. The brake plate 14 may be made from conventional metal or plastic, and in some embodiments, from steel (including stainless steel). The brake plate 14 is disposed on a side 26 of the rotor 12. The brake plate 14 may be further disposed about and centered on an axis 24. The brake plate 14 may be secured against rotation and coupled to the electromagnet 22 using a number of axially extending fasteners, such as bolts, pins, screws, etc.

[0028] The armature 16 is also configured to engage the rotor 12 during application of the brake to transmit braking torque to the rotor 12. The armature 16 may be made of a metal or metal alloy or other material having a relatively low magnetic reluctance, such as iron or steel. The armature 16 is disposed on a side 28 of the rotor 12. The armature 16 may be further disposed about and centered on an axis 24. The armature 16 is fixed against rotation but is axially movable toward and away from the rotor 12 and brake plate 14 to allow for engagement and disengagement of the brake. The armature 16 may include a number of bores extending therethrough or a number of recesses in a radially outer surface of the armature 16 configured to allow fasteners connecting the brake plate 12 and the electromagnet 22 to pass through the armature 16. In this manner, the fastener limits or prevents rotation of the armature 16 about the axis 24 , but allows the armature 16 to move along the axis 24 .

[0029] The spring 18 provides a means for biasing the armature 16 in one direction along the axis 24 toward the rotor 12 and brake plate 14 to engage the brake. The spring 18 may be disposed between the electromagnet 22 and the armature 16. It should be understood that the coupler 10 may include either a single annular spring 18 or multiple springs 18 arranged in an annular fashion about the axis 24. In the latter case, the springs 18 may be equally spaced circumferentially about the axis 24.

[0030] The spacer 20 is provided to position and orient the brake plate 14 and the electromagnet 22 relative to one another and, together with the brake plate 14 and the electromagnet 22, define an enclosed space that includes the rotor 12 and the armature 16. The spacer 22 may be made from conventional materials including metals such as aluminum or non-magnetic or relatively high magnetic resistance plastics. The spacer 22 may include a plurality of circumferentially equally spaced radially inwardly extending flanges that define fastener bores aligned with corresponding bores in the brake plate 14 and the electromagnet 22 and are configured to receive fasteners extending through the brake plate 14, the spacer 20 and the electromagnet 22 to join the brake plate 14, the spacer 20 and the electromagnet 22 together. When assembled, the spacer 20 is disposed radially outward of the rotor 12 and the armature 16 with one axial end of the spacer 20 abutting the brake plate 14 and the opposite axial end abutting the electromagnet 22.

[0031] The electromagnet 22 provides a means for biasing the armature 16 in a reverse direction along the axis 24, away from the rotor 12 and brake plate 14, to disengage the brake. The electromagnet 22 may include a field shell 30 and a conductor in the form of a coil 32 wound on a bobbin. The field shell 30 houses the coil 32 wound on a bobbin and may provide structural support and orientation for other components of the device 10, including the brake plate 14 and the spring 18. The field shell 30 may be annular in shape, disposed about and centered on the axis 24, and disposed on a side of the armature 16 opposite the rotor 12. The field shell 30 may be made of a material having a relatively low magnetic reluctance, such as a ferromagnetic material. The field shell 30 may define a radially extending end wall 34 and axially extending, radially aligned inner and outer walls 36 and 38 extending axially from the end wall 34 toward the armature 16. The outer wall 38 may define one or more closed bores 40 configured to receive one end of each spring 18. The outer wall 38 may also define one or more closed bores (not shown) configured to receive fasteners that couple the brake plate 14, the spacer 20, and the electromagnet 22. The bobbin-wound coil 32 is configured to be received within the field shell 30 between the walls 36 and 38. An electrical current supplied to the coil creates an electromagnetic circuit that includes the armature 16 and the field shell 30. The electromagnetic circuit urges the armature 16 toward the field shell 30 and away from the rotor 12 against the force of the spring 18 to disengage the brake.

[0032] 2-4, one embodiment of a bobbin wound coil 32 in accordance with the present teachings will now be described. The bobbin wound coil 32 includes a bobbin 42 and, with reference to FIGS. 9 and 10, a coil 44.

[0033] 2-4, a bobbin 42 is provided for positioning and orienting the coil 44. The bobbin 42 may be made from a conventional plastic or other material having relatively high magnetic resistance. The bobbin may include a body 46, end flanges 48, 50, and a terminal connector 52.

[0034] The body 46 may be cylindrical and disposed about and centered on a central axis, such as axis 24 in the electromagnetic coupler 10. The body 46 defines a central aperture configured to receive a portion of the field shell 30. With reference to FIG. 1, the radially inner surface of the body 46 may engage the inner wall 36 of the field shell 30. The radially outer surface of the body 46 is configured to support the coil 44 when it is wound on the bobbin 42. In the embodiment shown in FIGS. 2-4, the body 46 is cylindrical along its entire axial length. Now with reference to FIG. 5, in an alternative embodiment, the bobbin wound coil 54 may include means for preventing rotation of the bobbin wound coil 54 relative to the field shell 30, such as a rotation stop member in the form of one or more flats 56 extending from the bobbin body 58. The flats 56 may be formed on the radially inner surface of the bobbin body 58 and may extend along a portion or all of the axial length of the body 58. The flats 56 are configured to engage corresponding flats that may be formed on the walls 36 of the field shell 30. In this manner, rotation of the bobbin wound coil 54 relative to the field shell 30 resulting from forces during torque transmission in the coupler 10 is prevented.

[0035] 2-4, the end flanges 48, 50, together with the body 46, define a space configured to receive, position and retain the coil 44. The flanges 48, 50 are disposed at opposite axial ends of the body 46 and extend radially outward therefrom. With reference to FIG. 3, each flange 48, 50 defines an inner side 60, 62, respectively, facing the body 46 and an outer side 64, 66, respectively, facing away from the body 46. The outer side 64 of the flange 48 is configured to support the terminal connector 52.

[0036] The shape and axial thickness of the end flange 48 may vary. In particular, the shape and axial thickness of the end flange 48 may vary to accommodate the passage of the coil 44 from the body 46 to the terminal connector 52 and the location of the beginning portion of the coil 44. Referring now to FIG. 6, the flange 48 defines a pair of openings 68, 70 extending therethrough from an exterior side 64 of the flange 48 to an interior side 60 of the flange 48, through which beginning and end portions of the coil 44 may extend, respectively. A circumferential section 72 of the flange 48 adjacent the opening 68 has a smaller axial thickness than the other circumferential sections of the flange 48 such that a distance d1 from the interior side 60 of the section 72 of the end flange 48 to the interior side 62 of the end flange 50 is greater than a distance d2 from the interior side 60 of the other circumferential sections of the end flange 48 to the interior side 62 of the end flange 50. Section 72 is configured to receive a radially extending section of the beginning of coil 44 that extends along the inner side 60 of section 72 of end flange 48 between opening 68 and the radially outer surface of body 46 such that there is no interference with this section of the beginning of coil 44 as coil 44 continues to be wound around body 46.

[0037] 2, the axial thickness of the flange 48, along with inner and outer hubs or walls 76, 78 extending circumferentially around the radially inner and outer edges of the flange 48, radially define one or more recesses 74 in the outer side 64 of the end flange 48, and may further vary to define a plurality of spokes or side walls 80 extending between the walls 76, 78 and adjacent recesses 74. The walls 76, 78, 80 provide strength enhancement to the flange 48, while the recesses 74 help reduce the weight of the flange 48 and the amount of material used to form the flange 48. Now referring to FIG. 7, each recess 74 in the outer side 64 of the flange 48 is adjacent a pair of opposed inner and outer walls 76 and 78 and adjacent opposed side walls 80. Depending on the application and operating environment of the coupling machine 10, the bobbin wound coil 32 may be exposed to fluids or other debris that may potentially collect in the recesses 74. According to one aspect of the invention, one or more openings 82 may be formed in the outer wall 78 in communication with the recess 74 to allow any fluid and other debris collected in the recess 74 to exit the recess 74. A fillet may be formed between a surface defining the bottom of the recess 74 and a surface of the wall 78 to facilitate the exit of fluids and debris.

[0038] 2-4, the end flange 50 may have a uniform or substantially uniform axial thickness. However, and now referring to FIG. 8, in an alternative embodiment, the bobbin wound coil 84 may include means for preventing rotation of the bobbin wound coil 84 relative to the field shell 30, such as anti-rotation members in the form of one or more lugs 86 extending axially from the flange 88. The lugs 86 may be formed on the exterior side of the flange 88 and configured to engage corresponding recesses formed in the wall 34 of the field shell 30. In this manner, rotation of the bobbin wound coil 84 relative to the field shell 30 resulting from forces during torque transmission in the coupler 10 is prevented. The lugs 86 may also facilitate proper orientation of the bobbin wound coil 84 relative to the field shell 30 during assembly of the coupler 10.

[0039] 2-4, the terminal connector 52 provides a means for connecting the coil 44 to an external power source. The connector 52 may be formed as a unitary (integral) structure with the body 46 and the flanges 48, 50. The connector 52 may be disposed on the exterior side 64 of the flange 48 adjacent the radially outer edge of the flange 48. Now, with reference to FIG. 9, the connector 52 includes a body 90 including axially spaced inner and outer walls 92, 94, circumferentially spaced sidewalls 96, 98 extending between the walls 92, 94, and, with reference to FIG. 4, a radially inner sidewall 100 extending between the walls 92, 94. Referring again to FIG. 9, the body 96 defines a central cavity 102 adjacent the walls 92, 94, 96, 98, 100 configured to receive a pair of terminal pins 104, 106 that are supported within the cavity 102 and, when the coupler 10 is assembled, make contact with portions of the coil 44 and mating electrical contacts within a corresponding terminal connector of an external power source (not shown) received within the cavity 102.

[0040] 3, the outer wall 94 may include one or more locking tabs 108 extending from an outer surface of the wall 94 of the body 90 for securing the connection between the terminal connector 52 and the terminal connector of the external power source. In the illustrated embodiment, the connector 52 includes a single tab 108 near the radially outer end of the body 90 of the connector 52. The tab 108 may be of generally triangular cross-section, and in particular may include a right-angled triangle having an edge 110 extending radially along the surface of the wall 94, an axially extending edge 112 extending from the wall 94, and a sloped edge 114 or incline extending between the edges 110 and 112. As the terminal connector of the external power source moves toward the terminal connector 52, the tab 108 biases a corresponding locking element on the terminal connector of the external power source from a normal position and away from the wall 94 of the terminal connector 52 as the locking element moves along the edge 114 of the tab 108. When the locking element reaches the end of edge 114 adjacent edge 112, the locking element returns to its normal position and tab 108 moves toward wall 94 of terminal connector 52 to prevent movement of the terminal connector of the external power source away from terminal connector 52 and separation between the two connectors.

[0041] 2, in accordance with another aspect of the teachings herein, the outer wall 100 may include a plurality of posts 116, 118, 120, 122 extending from an outer surface of the wall 94 of the body 90 proximate a radially inner end of the body 90 of the terminal connector 52. The posts 116, 118, 120, 122 provide protection for the tab 108 during shipping and handling of the bobbin-wound coil 32 and coupler 10, and at least one of the posts (post 120 in the illustrated embodiment) may be radially aligned with the tab 108. Referring again to FIG. 9, the posts 116, 118, 120, 122 also provide a means for tensioning the coil 44 during winding of the coil 44 on the bobbin 42 and during insertion of the terminal pins 104, 106 into the cavity 102 of the terminal connector 52 and contacting the coil 44. In particular, when the coil 44 begins to wind, the beginning portion of the coil 44 is first wound around the posts 116, 118 before entering the cavity 102 of the terminal connector 52, providing tension to the coil 44 as it is wound through the connector 52 and the flange 48 onto the body 46 of the bobbin 42. Similarly, when the coil 44 ends to wind, the end portion of the coil 44 is wound around the posts 120, 122 before exiting the cavity 102 of the terminal connector 52, providing sufficient tension to the end portion of the coil 44 when the terminal pins 104, 106 are inserted into the cavity 102 and contact the coil 44. Although two posts 116, 118 and 120, 122 are used to wind the beginning and end portions of the coil 44, respectively, in the illustrated embodiment, it should be understood that the number of posts may vary and that the beginning and end portions of the coil 44 may each be wound around a single post, for example.

[0042] The inner and outer walls 92, 94 of the terminal connector 52 include pairs of openings 124, 126 and 128, 130, respectively, in the form of generally radially extending slots configured to receive beginning and ending portions of the coil 44 during winding of the coil 44 on the bobbin 42. The openings 124, 126 and 128, 130 in the walls 92, 94 extend from a radially outer edge of each wall 92, 94 to a position adjacent the radially inner edge of each wall 92, 94 and adjacent the radially inner sidewall 100, respectively. The openings 124, 128 may be aligned with one another. The openings 126, 130 may be aligned with one another as well. The openings 124, 126 and 128, 130 effectively divide each of the inner and outer walls 92, 94 into three separate sections. In particular, the openings 124, 126 divide the wall 92 into a pair of circumferential end sections 132, 134 and a central section 136 disposed between the circumferential end sections 132 and 134 and separated from the circumferential end sections 132, 134 by the openings 124, 126. Similarly, the openings 128, 130 divide the wall 94 into a pair of circumferential end sections 138, 140 and a central section 142 disposed between the circumferential end sections 138 and 140 and separated from the circumferential end sections 138, 140 by the openings 118, 130. In accordance with another aspect of the teachings herein, a portion of one or more of the sections 132, 134, 136 of the inner wall 92 may define a recess 144 away from the sidewall 100 and configured to receive a portion of the coil 44. These recesses 144 facilitate proper placement and retention of the beginning and / or ending portions of the coil 44 within the cavity 102 of the terminal connector 52, and particularly within the upper and lower saddles for the coil 44 formed in the connector 52 on either side of the terminal pins 104, 106, when a winding nozzle used to dispense the coil 44 and wind the coil 44 onto the bobbin 42 exits the connector 52, thereby ensuring proper tensioning of the coil 44 and ultimately proper connection of the terminals 104, 106 with the beginning and ending portions of the coil 44. In the illustrated embodiment, the recesses 144 are formed in a portion of the section 136 of the inner wall 92 adjacent the opening 126 to receive the ending portions of the coil 44.However, it should be understood that a similar recess may be formed in a portion of section 136 adjacent opening 124 to receive a beginning portion of coil 44, or may be formed in either end portions 132, 134 adjacent openings 124, 126, respectively, to receive either a beginning or end portion of coil 44.

[0043] 9 and 10, the coil 44 is provided to conduct current provided by an external power source to establish an electromagnetic circuit between the armature 16 and the field shell 30 that attracts the armature 16 toward the field shell 30 and releases the brake. The coil 44 may include a wire made of copper or other conductive material. The coil 44 may be wound around the bobbin 42 using a conventional coil winding machine in which the coil 44 is dispensed from a nozzle that performs a series of predetermined movements relative to the bobbin 42. Referring to FIG. 10, winding the bobbin 42 may begin by winding a starting portion 146 of the coil 44 around the posts 116, 118. Referring to FIG. 9, the starting portion 146 of the winding 44 is then fed through an opening 128 in the outer wall 94 of the terminal connector 52 and an opening 124 in the inner wall 92 of the terminal connector 52. As previously mentioned, the portion 146 of the winding 44 may be located within a recess 144 formed in the section 132 or section 136 of the inner wall 92 adjacent the opening 124, if such a recess is provided. Referring again to FIG. 6, after exiting the opening 124 in the inner wall 92 of the terminal connector 52, the portion 146 of the coil 44 is then fed through the opening 68 in the flange 48. Referring again to FIG. 10, according to one aspect of the present teachings, a section 148 of the portion 146 of the coil 44 extends circumferentially from the opening 124 in the inner wall 92 of the terminal connector 52, past the opening 126 in the inner wall 92 of the terminal connector 52, to the opening 68 in the end flange 48. The coil 44 is then further wound such that another section 150 of the beginning portion 146 of the coil 44 extends radially inward from the section 148. 6, section 148 extends along the interior side of circumferential section 72 of end flange 48 toward body 46. The central portion of coil 44 extending between the beginning and ending portions of coil 44 is then repeatedly wound around body 46 until a predetermined amount of coil 44 is wound around 46. End portion 152 (see FIG. 10) of coil 44 is then fed through opening 70 in end flange 48 and, referring to FIG. 9, through opening 126 in inner wall 92 of terminal connector 52.10 , in accordance with the present teachings, the end portion 152 of the coil 44 is positioned such that the section 154 of the end portion 152 of the coil 44 extends circumferentially from the opening 126 in the inner wall 92 of the terminal connector 52 to the opening 70 in the end flange 48, past the opening 124 in the inner wall 92 of the terminal connector 52, such that the section 154 of the end portion 152 of the coil 44 extends beyond the section 148 of the beginning portion 146 of the coil 44. This arrangement and configuration of the portions 146, 152 of the coil 44 inside the terminal connector 52 allows the section 150 of the beginning portion 146 of the coil 44 to be positioned in a position that does not interfere with the subsequent winding of the coil 44 about the body 46, thereby eliminating any need for an outwardly protruding ridge on the exterior side of the end flange 48 to accommodate the coil 44 and improving manufacturability and packaging of the bobbin wound coil 32. Once through the opening 126 in the inner wall 92 of the terminal connector 52, the end portion 152 may be positioned within a recess 144 formed in the central section 136 of the inner wall 92 (or a similar recess 144 formed in the circumferential end section 134 of the inner wall 92). The end portion 152 then passes through the opening 130 in the outer wall 94 and is wound around the posts 120, 122, after which the coil is cut.

[0044] The bobbin wound coil 32 according to the teachings herein represents an improvement over conventional bobbin wound coils used in electromagnetic couplers. In particular, in one embodiment, the bobbin wound coil 32 is configured to eliminate any need for an outwardly protruding ridge on the exterior side of the end flange 48 to accommodate typical winding patterns, thereby improving manufacturability and packaging. In another embodiment, the bobbin wound coil 32 is configured to facilitate tensioning of the beginning portion 146 and / or the end portion 152 of the coil 44 and / or securing of the beginning portion 146 and / or the end portion 152 of the coil 44 within the terminal connector 52 of the bobbin 42 during winding of the coil 44. In another embodiment, the bobbin 42 is configured to prevent accumulation of liquids or debris in the recess 74 formed in the exterior side 64 of the end flange 48 to balance the competing goals of strengthening the end flange 48 while reducing weight and material costs. In other embodiments 54 or 84 , the bobbin is further configured to prevent relative rotation of the bobbin and the field shell 30 in the electromagnetic coupler 10 .

[0045] Further statements of the invention are set forth below.

[0046] Statement 1. A bobbin wound coil for an electromagnetic coupler, the bobbin including a cylindrical body disposed about a central axis, a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, and a terminal connector on the outer side of the first end flange, a first opening in the terminal connector and a start portion extending through the first opening in the first end flange, a second opening in the terminal connector and a start portion extending through the first opening in the first end flange, A bobbin wound coil including a coil having a terminal portion extending through a second opening in one end flange, where the second opening in the terminal connector is in front of the first opening in the terminal connector in a first circumferential direction and the second opening in the first end flange is behind the first opening in the first end flange in the first circumferential direction, the starting portion includes a first section extending from the first opening in the terminal connector to the first opening in the first end flange and the ending portion includes a first section extending from the second opening in the terminal connector to the second opening in the first end flange, the first section of the ending portion of the coil extending beyond the first section of the starting portion of the coil.

[0047] Statement 2. A bobbin wound coil as described in Statement 1, wherein a first section of a beginning portion of the coil extends beyond a second opening in the terminal connector, and a first section of a terminal portion of the coil extends beyond the first opening in the terminal connector.

[0048] Statement 3. A coil wound on a bobbin as described in either Statement 1 or 2, wherein the first end flange includes first and second circumferential sections having different axial thicknesses such that a first distance from an inner side of the second end flange to the inner side of the first end flange at the first circumferential section of the first end flange is greater than a second distance from the inner side of the second end flange to the inner side of the first end flange at the second circumferential section of the first end flange, and the beginning portion of the coil includes a second section extending radially inward from the first section of the beginning portion of the coil and along the inner side of the first end flange at the first circumferential section of the first end flange.

[0049] Statement 4. A coil wound on a bobbin as described in Statement 3, wherein a second section of the beginning portion of the coil extends radially inwardly along an inner side of the first end flange at a first circumferential section of the first end flange from a first opening in the first end flange of the bobbin to a cylindrical body of the bobbin.

[0050] Statement 5. A bobbin-wound coil as described in any one of Statements 1-4, wherein the axial thickness of the first end flange varies adjacent a radial inner wall, a radial outer wall, and first and second side walls extending radially between the radial inner wall and the radial outer wall to define a first recess on an exterior side of the first end flange, the radial outer wall including a first opening extending therethrough and in communication with the first recess.

[0051] Statement 6. A bobbin-wound coil according to any one of statements 1-5, wherein the terminal connector includes a body defining a central cavity and a post extending from an outer surface of the body of the terminal connector, and one of the beginning and ending portions of the coil is wound around the post.

[0052] Statement 7. The bobbin wound coil of Statement 6, further comprising a locking tab extending from an outer surface of the body of the terminal connector, the post being radially aligned with the locking tab.

[0053] Statement 8. A terminal connector includes a body defining a central cavity and including axially spaced inner and outer walls, first and second circumferentially spaced sidewalls extending between the inner and outer walls, and a radially inner sidewall extending between the inner and outer walls, the inner wall of the body of the terminal connector including first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by corresponding ones of the first and second openings in the terminal connector, and a portion of the first circumferential end section, the second circumferential end section and one of the central sections defines a first recess away from the radially inner sidewall configured to receive one of the beginning and ending portions of the coil.

[0054] Statement 9. The bobbin-wound coil of any one of statements 1 to 8, further comprising a rotation-stop member extending from one of the cylindrical body, the first end flange, and the second end flange and configured to engage a field shell of an electromagnetic coupler.

[0055] Statement 10. A coil wound on a bobbin according to any one of statements 1 to 8, further comprising means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0056] Statement 11. A method of forming a bobbin wound coil for an electromagnetic coupler, comprising: providing a bobbin including a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a terminal connector on the outer side of the first end flange. and inserting a starting portion of the coil through a first opening in the first end flange and a first opening in the first end flange; winding the coil around the cylindrical body; and inserting an end portion of the coil through a second opening in the first end flange rearward of the first opening in the first end flange in a first circumferential direction and a second opening in the terminal connector forward of the first opening in the terminal connector in the first circumferential direction such that a first section of the end portion of the coil extending from the second opening in the first end flange to the second opening in the terminal connector exceeds a first section of the start portion of the coil extending from the first opening in the terminal connector to the first opening in the first end flange.

[0057] Statement 12. A method of forming a bobbin wound coil for an electromagnetic coupler as described in Statement 11, wherein a first section of a beginning portion of the coil extends beyond a second opening in the terminal connector, and a first section of a terminal portion of the coil extends beyond the first opening in the terminal connector.

[0058] Statement 13. A method of forming a bobbin wound coil for an electromagnetic coupling machine as described in either of statements 11 or 12, wherein the first end flange includes first and second circumferential sections having different axial thicknesses such that a first distance from an inner side of the second end flange to the inner side of the first end flange at the first circumferential section of the first end flange is greater than a second distance from the inner side of the second end flange to the inner side of the first end flange at the second circumferential section of the first end flange, the method further including placing from the first section of the coil a second section of the coil beginning extending along the inner side of the first end flange at the first circumferential section of the first end flange.

[0059] Statement 14. The method of forming a bobbin wound coil for an electromagnetic coupling machine as described in Statement 13, wherein placing the second section of the coil start portion includes positioning the second section of the coil start portion such that the second section of the coil start portion extends radially inward along an inner side of the first end flange at a first circumferential section of the first end flange from a first opening in the first end flange of the bobbin to a cylindrical body of the bobbin.

[0060] Statement 15. A method of forming a bobbin wound coil for an electromagnetic coupling machine as described in any one of Statements 11 to 14, wherein an axial thickness of the first end flange varies adjacent a radial inner wall, a radial outer wall, and first and second side walls extending radially between the radial inner wall and the radial outer wall to define a first recess on an exterior side of the first end flange, the radial outer wall including a first opening extending therethrough and in communication with the first recess.

[0061] Statement 16. A method of forming a bobbin wound coil for an electromagnetic coupler as described in any one of statements 11-15, wherein the terminal connector includes a body defining a central cavity and a post extending from an outer surface of the body of the terminal connector, and the method further includes winding one of the beginning and ending portions of the coil around the post.

[0062] Statement 17. A method of forming a bobbin wound coil for an electromagnetic coupler as described in statement 16, wherein the terminal connector includes a locking tab extending from an outer surface of the body of the terminal connector, and the post is radially aligned with the locking tab.

[0063] Statement 18. The method of forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 11 to 17, wherein the terminal connector includes a body defining a central cavity and including axially spaced inner and outer walls, first and second circumferentially spaced side walls extending between the inner and outer walls, and a radially inner side wall extending between the inner and outer walls, the inner wall of the body of the terminal connector including first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by corresponding ones of the first and second openings in the terminal connector, and a portion of the first circumferential end section, the second circumferential end section and one of the central sections defines a first recess away from the radially inner side wall configured to receive one of the beginning and ending portions of the coil.

[0064] Statement 19. A method of forming a bobbin wound coil for an electromagnetic coupler described in any one of statements 11-18, wherein the bobbin further includes a rotation stop member extending from one of the cylindrical body, the first end flange, and the second end flange, and configured to engage a field shell of the electromagnetic coupler.

[0065] Statement 20. A method of forming a bobbin wound coil for an electromagnetic coupler according to any one of statements 11 to 18, wherein the bobbin further includes means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0066] Statement 21. A bobbin wound coil for an electromagnetic coupler, comprising: a bobbin including a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a terminal connector on the outer side of the first end flange, the terminal connector including a body defining a central cavity and including axially spaced inner and outer walls, first and second circumferentially spaced side walls extending between the inner and outer walls, and a radially inner side wall extending between the inner and outer walls; and a coil, a bobbin-wound coil including a coil having a starting portion extending through a first opening in each of the inner and outer walls of the terminal connector body, a terminal portion extending through a second opening in each of the inner and outer walls of the terminal connector body, and a central portion extending between the starting portion and the terminal portion and wound around a cylindrical body, the inner wall of the terminal connector body including first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by corresponding ones of the first and second openings in the inner wall, and a portion of the first circumferential end section, the second circumferential end section and one of the central sections defining a first recess away from a radially inner sidewall configured to receive one of the coil starting portion and the terminal portion.

[0067] Statement 22. The bobbin wound coil of statement 21, wherein another portion of the first circumferential end section, the second circumferential end section, and one of the central sections defines a second recess away from the radially inner wall and configured to receive the other of the beginning and ending portions of the coil.

[0068] Statement 23. A bobbin wound coil as described in either of statements 21 or 22, wherein a first portion of the central section defines a first recess away from the radially inner sidewall, and the first recess is configured to receive a terminal portion of the coil.

[0069] Statement 24. The bobbin wound coil of statement 23, wherein the second portion of the central section defines a second recess away from the radially inner sidewall, and the second recess is configured to receive a starting portion of the coil.

[0070] Statement 25. A bobbin wound coil as described in either of statements 21 or 22, wherein a first portion of the central section defines a first recess away from the radially inner sidewall, and the first recess is configured to receive a starting portion of the coil.

[0071] Statement 26. A bobbin-wound coil according to any one of Statements 21 to 25, wherein a starting portion of the coil extends through a first opening in the first end flange, and a terminal portion of the coil extends through a second opening in the first end flange, the second opening in the inner wall of the terminal connector is in front of the first opening in the inner wall of the terminal connector in the first circumferential direction, and the second opening in the first end flange is behind the first opening in the first end flange in the first circumferential direction, the starting portion of the coil includes a first section extending from the first opening in the inner wall of the terminal connector to the first opening in the first end flange, and the terminal portion includes a first section extending from the second opening in the inner wall of the terminal connector to the second opening in the first end flange, and the first section of the terminal portion of the coil extends beyond the first section of the starting portion of the coil.

[0072] Statement 27. A bobbin-wound coil as described in any one of Statements 21 to 26, wherein the axial thickness of the first end flange varies adjacent a radially inner wall, a radially outer wall, and first and second side walls extending radially between the radially inner wall and the radially outer wall to define a first recess on an exterior side of the first end flange, the radially outer wall including a first opening extending therethrough and in communication with the first recess.

[0073] Statement 28. A bobbin wound coil according to any one of statements 21 to 27, wherein the terminal connector includes a post extending from an outer surface of the body of the terminal connector, and one of the beginning and ending portions of the coil is wound around the post.

[0074] Statement 29. The bobbin wound coil of any one of statements 21-28, further comprising a rotation stop member extending from one of the cylindrical body, the first end flange and the second end flange and configured to engage a field shell of an electromagnetic coupler.

[0075] Statement 30. A coil wound on a bobbin according to any one of statements 21 to 28, further comprising means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0076] Statement 31. A method of forming a bobbin wound coil for an electromagnetic coupler, comprising providing a bobbin comprising: a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a terminal connector on the outer side of the first end flange, the second end flange defining a central cavity and having axially spaced inner and outer walls, first and second circumferentially spaced side walls extending between the inner and outer walls, and a radially spaced side wall extending between the inner and outer walls. a terminal connector including a body including an inner sidewall, the inner wall of the terminal connector body including first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by first and second openings in the inner wall, the first circumferential end section, the second circumferential end section and a portion of the central section defining a first recess away from the radially inner sidewall; inserting a starting portion of a coil through the first opening in the inner wall of the terminal connector; winding the coil around a cylindrical body; and inserting a terminal portion of the coil through the second opening in the inner wall of the terminal connector, wherein one of the starting and ending portions of the coil extends through the first recess.

[0077] Statement 32. A method of forming a bobbin wound coil for an electromagnetic coupler as described in Statement 31, wherein another portion of the first circumferential end section, the second circumferential end section and one of the central sections defines a second recess away from the radially inner wall, and the other of the beginning and ending portions of the coil extends through the second recess.

[0078] Statement 33. A method of forming a bobbin wound coil for an electromagnetic coupler as described in either of statements 31 or 32, wherein a first portion of the central section defines a first recess away from the radially inner sidewall, and a terminal portion of the coil extends through the first recess.

[0079] Statement 34. A method of forming a bobbin wound coil for an electromagnetic coupler as described in Statement 33, wherein a second portion of the central section defines a second recess away from the radially inner sidewall, and a starting portion of the coil extends through the second recess.

[0080] Statement 35. A method of forming a bobbin wound coil for an electromagnetic coupler as described in either of statements 31 or 32, wherein a first portion of the central section defines a first recess away from the radially inner sidewall, and a starting portion of the coil extends through the first recess.

[0081] Statement 36. A method of forming a coil wound on a bobbin for an electromagnetic coupler according to any one of Statements 31 to 35, comprising inserting a starting portion of the coil through a first opening in the first end flange and inserting a terminal portion of the coil through a second opening in the first end flange, wherein the second opening in the inner wall of the terminal connector is in front of the first opening in the inner wall of the terminal connector in the first circumferential direction and the second opening in the first end flange is behind the first opening in the first end flange in the first circumferential direction, the starting portion of the coil includes a first section extending from the first opening in the inner wall of the terminal connector to the first opening in the first end flange, and the terminal portion includes a first section extending from the second opening in the inner wall of the terminal connector to the second opening in the first end flange, and the first section of the terminal portion of the coil extends beyond the first section of the starting portion of the coil.

[0082] Statement 37. A method of forming a bobbin wound coil for an electromagnetic coupling machine as described in any one of Statements 31 to 36, wherein an axial thickness of the first end flange varies adjacent a radial inner wall, a radial outer wall, and first and second side walls extending radially between the radial inner wall and the radial outer wall to define a first recess on an exterior side of the first end flange, the radial outer wall including a first opening extending therethrough and in communication with the first recess.

[0083] Statement 38. A method of forming a bobbin wound coil for an electromagnetic coupler according to any one of statements 31-37, wherein the terminal connector includes a post extending from an outer surface of a body of the terminal connector, and the method further includes winding one of the beginning and ending portions of the coil around the post.

[0084] Statement 39. A method of forming a bobbin wound coil for an electromagnetic coupler described in any one of statements 31-38, wherein the bobbin further includes a rotation stop member extending from one of the cylindrical body, the first end flange, and the second end flange, and configured to engage a field shell of the electromagnetic coupler.

[0085] Statement 40. A method of forming a bobbin wound coil for an electromagnetic coupler according to any one of statements 31 to 38, wherein the bobbin further includes means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0086] Statement 41. A coil wound on a bobbin for an electromagnetic coupling machine, the bobbin comprising: a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a second end flange extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. a bobbin including a terminal connector on the side, the terminal connector including a body defining a central cavity and a first post extending from an outer surface of the body of the terminal connector; and a coil wound on the bobbin, the coil having a starting portion extending through the body and first end flange of the terminal connector, a terminal portion extending through the body and first end flange of the terminal connector, and a central portion extending between the starting portion and the terminal portion and wound around the cylindrical body of the bobbin, wherein one of the starting portion and the terminal portion of the coil is wound around the first post.

[0087] Statement 42. The bobbin wound coil of statement 41, further comprising a locking tab extending from an outer surface of the body of the terminal connector, the first post being radially aligned with the locking tab.

[0088] Statement 43. A bobbin wound coil as described in Statement 42, wherein the locking tab is triangular in cross section and includes a radially extending edge along an outer surface of the body of the terminal connector, an axially extending edge extending away from the outer surface of the body of the terminal connector, and a beveled edge extending between the radially extending edge and the axially extending edge.

[0089] Statement 44. The bobbin wound coil of any one of statements 41-43, wherein the terminal connector further includes a second post extending from an outer surface of the body of the terminal connector, and the other of the starting and ending portions of the coil is wound around the second post.

[0090] Statement 45. The bobbin wound coil of statement 44, wherein the terminal connector includes third and fourth posts extending from an outer surface of the body of the terminal connector, a beginning portion of the coil wound around two of the first, second, third and fourth posts, and a terminal portion of the coil wound around another two of the first, second, third and fourth posts.

[0091] Statement 46. A bobbin-wound coil according to any one of statements 41 to 45, wherein a starting portion of the coil extends through a first opening in the terminal connector and a first opening in the first end flange, and a terminal portion of the coil extends through a second opening in the terminal connector and a second opening in the first end flange, the second opening in the terminal connector is in front of the first opening in the terminal connector in the first circumferential direction, and the second opening in the first end flange is behind the first opening in the first end flange in the first circumferential direction, the starting portion of the coil includes a first section extending from the first opening in the terminal connector to the first opening in the first end flange, and the terminal portion of the coil includes a first section extending from the second opening in the terminal connector to the second opening in the first end flange, and the first section of the terminal portion of the coil extends beyond the first section of the starting portion of the coil.

[0092] Statement 47. A bobbin-wound coil as described in any one of Statements 41-46, wherein the body of the terminal connector includes axially spaced inner and outer walls, first and second circumferentially spaced side walls extending between the inner and outer walls, and a radially inner side wall extending between the inner and outer walls, the inner wall of the body of the terminal connector includes first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by first and second openings in the terminal connector, and a portion of the first circumferential end section, the second circumferential end section, and one of the central sections defines a first recess away from the radially inner side wall configured to receive one of the beginning and ending portions of the coil.

[0093] Statement 48. A bobbin-wound coil as described in any one of Statements 41 to 47, wherein the axial thickness of the first end flange varies adjacent a radially inner wall, a radially outer wall, and first and second side walls extending radially between the radially inner wall and the radially outer wall to define a first recess on an exterior side of the first end flange, the radially outer wall including a first opening extending therethrough and in communication with the first recess.

[0094] Statement 49. The bobbin wound coil of any one of statements 41-48, further comprising a rotation stop member extending from one of the cylindrical body, the first end flange, and the second end flange, and configured to engage a field shell of an electromagnetic coupler.

[0095] Statement 50. A coil wound on a bobbin according to any one of statements 41 to 48, further comprising means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0096] Statement 51. A method of forming a bobbin wound coil for an electromagnetic coupler, the method including: providing a bobbin including a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing the cylindrical body; a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing the cylindrical body; and a terminal connector on the outer side of the first end flange, the terminal connector including a body defining a central cavity and a first post extending from an outer surface of the body of the terminal connector; inserting a starting portion of the coil through the terminal connector and the first end flange; winding the coil around the cylindrical body; inserting a terminal portion of the coil through the first end flange and the terminal connector; and winding one of the starting and terminal portions of the coil around the first post.

[0097] Statement 52. The method of forming a bobbin wound coil for an electromagnetic coupler as described in statement 51, wherein the terminal connector includes a locking tab extending from an outer surface of the body of the terminal connector, and the first post is radially aligned with the locking tab.

[0098] Statement 53. A method of forming a bobbin wound coil for an electromagnetic coupler as described in Statement 52, wherein the locking tab is triangular in cross section and includes a radially extending edge along an outer surface of the body of the terminal connector, an axially extending edge extending away from the outer surface of the body of the terminal connector, and a beveled edge extending between the radially extending edge and the axially extending edge.

[0099]

[0100] Statement 54. A method of forming a bobbin wound coil for an electromagnetic coupler as described in any one of statements 51-53, wherein the terminal connector further includes a second post extending from an outer surface of the body of the terminal connector, and the method includes winding the other of the starting and ending portions of the coil around the second post.

[0101] Statement 55. A method of forming a bobbin wound coil for an electromagnetic coupler as described in statement 54, wherein the terminal connector includes third and fourth posts extending from an outer surface of a body of the terminal connector, and the method includes winding one of the beginning and ending portions of the coil around the third post and winding the other of the beginning and ending portions of the coil around the fourth post.

[0102] Statement 56. The method of forming a bobbin wound coil for an electromagnetic coupler according to any one of statements 51 to 55, further comprising inserting a starting portion of the coil through a first opening in the terminal connector and a first opening in the first end flange, and inserting a terminal portion of the coil through a second opening in the terminal connector and a second opening in the first end flange, wherein the second opening in the terminal connector is in front of the first opening in the terminal connector in the first circumferential direction, and the second opening in the first end flange is behind the first opening in the first end flange in the first circumferential direction, the starting portion of the coil includes a first section extending from the first opening in the terminal connector to the first opening in the first end flange, and the terminal portion of the coil includes a first section extending from the second opening in the terminal connector to the second opening in the first end flange, and the first section of the terminal portion of the coil exceeds the first section of the starting portion of the coil.

[0103] Statement 57. The method of forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 51-56, wherein the body of the terminal connector includes axially spaced inner and outer walls, first and second circumferentially spaced side walls extending between the inner and outer walls, and a radially inner side wall extending between the inner and outer walls, the inner wall of the body of the terminal connector includes first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by first and second openings in the terminal connector, and a portion of the first circumferential end section, the second circumferential end section and one of the central section define a first recess away from the radially inner side wall, the method further including inserting a starting portion of the coil through the first opening in the inner wall of the terminal connector and inserting a terminal portion of the coil through the second opening in the inner wall of the terminal connector, one of the starting and terminal portions of the coil extending through the first recess.

[0104] Statement 58. A method of forming a bobbin wound coil for an electromagnetic coupling machine as described in any one of statements 51 to 57, wherein an axial thickness of the first end flange varies adjacent a radial inner wall, a radial outer wall, and first and second side walls extending radially between the radial inner wall and the radial outer wall to define a first recess on an exterior side of the first end flange, the radial outer wall including a first opening extending therethrough and in communication with the first recess.

[0105] Statement 59. A method of forming a bobbin wound coil for an electromagnetic coupler as described in any one of statements 51-58, wherein the bobbin further includes a rotation stop member extending from one of the cylindrical body, the first end flange, and the second end flange, and configured to engage a field shell of the electromagnetic coupler.

[0106] Statement 60. A method of forming a bobbin wound coil for an electromagnetic coupler according to any one of statements 51 to 59, wherein the bobbin further includes means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0107] Statement 61. A bobbin for a coil for an electromagnetic coupling machine, comprising: a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing the cylindrical body; and a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing the cylindrical body, the axial thickness of the first end flange varying adjacent a radial inner wall, a radial outer wall, and first and second side walls extending radially between the radial inner wall and the radial outer wall to define a first recess on the outer side of the first end flange, the radial outer wall including a first opening extending therethrough and in communication with the first recess.

[0108] Statement 62. The bobbin of statement 61, wherein the first side wall is disposed between the first recess and the second recess on an exterior side of the first end flange.

[0109] Statement 63. The bobbin of statement 61, wherein the first end flange defines a second recess on an exterior side of the first end flange adjacent a radially inner wall, a radially outer wall, and third and fourth side walls extending radially between the radially inner and radially outer walls, the radially outer wall including a second opening extending therethrough and in communication with the second recess.

[0110] Statement 64. A bobbin for a coil for an electromagnetic coupler, the bobbin including: a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a rotation stop member extending from one of the cylindrical body, the first end flange, and the second end flange and configured to engage a field shell of the electromagnetic coupler.

[0111] Statement 65. The bobbin of statement 64, wherein the anti-rotation member includes a first flat formed on a radially inner surface of the cylindrical body and configured to engage with a second flat on the field shell.

[0112] Statement 66. The bobbin of statement 64, wherein the anti-rotation member includes a lug extending from one of the first end flange and the second end flange into a recess in the field shell.

[0113] Statement 67. A bobbin for a coil for an electromagnetic coupler, the bobbin including: a cylindrical body disposed about a central axis; a first end flange disposed at a first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange disposed at a second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and means for preventing rotation of the bobbin relative to a field shell of the electromagnetic coupler.

[0114] Statement 68. The bobbin of statement 67, wherein the means for preventing rotation of the bobbin relative to the field shell includes a first flat formed on a radially inner surface of the cylindrical body and configured to engage a second flat on the field shell.

[0115] Statement 69. The bobbin of statement 67, wherein the means for preventing rotation of the bobbin relative to the field shell includes a lug extending from one of the first end flange and the second end flange into a recess in the field shell.

[0116] Although the invention has been shown and described with reference to one or more specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention.

Claims

1. A coil wound on a bobbin for an electromagnetic coupling machine, It is a bobbin, A cylindrical body arranged around a central axis, A first end flange disposed at the first axial end of the cylindrical body and extending radially outward therefrom, the first end flange defining the inner side facing the cylindrical body and the outer side facing away from the cylindrical body, A second end flange disposed at the second axial end of the cylindrical body and extending radially outward therefrom, the second end flange defining the inner side facing the cylindrical body and the outer side facing away from the cylindrical body, and Terminal connector on the outer side of the first end flange A bobbin containing, A coil having a starting portion extending through a first opening in the terminal connector and a first opening in the first end flange, and a ending portion extending through a second opening in the terminal connector and a second opening in the first end flange, wherein the second opening in the terminal connector is in front of the first opening in the terminal connector in a first circumferential direction, and the second opening in the first end flange is in behind the first opening in the first end flange in a first circumferential direction, the starting portion includes a first section extending from the first opening in the terminal connector to the first opening in the first end flange, and the ending portion includes a first section extending from the second opening in the terminal connector to the second opening in the first end flange, the first section of the ending portion of the coil extends beyond the first section of the starting portion of the coil, and A coil wound on a bobbin, including the coil itself.

2. A coil wound on a bobbin according to claim 1, wherein the first section of the starting portion of the coil extends beyond the second opening in the terminal connector, and the first section of the ending portion of the coil extends beyond the first opening in the terminal connector.

3. A coil wound on a bobbin according to claim 1 or 2, wherein the first end flange comprises first and second circumferential sections having different axial thicknesses such that a first distance from the inner side of the second end flange to the inner side of the first end flange in the first circumferential section of the first end flange is greater than a second distance from the inner side of the second end flange to the inner side of the first end flange in the second circumferential section of the first end flange, and the starting portion of the coil comprises a second section extending radially inward from the first section of the starting portion of the coil along the inner side of the first end flange in the first circumferential section of the first end flange.

4. The coil wound on a bobbin according to claim 3, wherein the second section of the starting portion of the coil extends radially inward along the inner side of the first end flange in the first circumferential section of the first end flange from the first opening in the first end flange of the bobbin to the cylindrical body of the bobbin.

5. The terminal connector includes a body comprising an inner wall and an outer wall that define a central cavity and are spaced apart in the axial direction, first and second circumferentially spaced side walls extending between the inner wall and the outer wall, and a radially inward side wall extending between the inner wall and the outer wall, wherein the inner wall of the body of the terminal connector includes first and second circumferential end sections and a central section disposed between the first and second circumferential end sections and separated from the first and second circumferential end sections by corresponding first and second openings in the terminal connector, and a portion of the first circumferential end section, the second circumferential end section and the central section defines a first recess configured to receive one of the starting and ending portions of the coil, the coil wound on a bobbin according to claim 1 or 2.

6. A coil wound on a bobbin according to claim 5, wherein one part of the first circumferential end section, the second circumferential end section, and the central section defines a second recess configured to receive the other of the starting and ending portions of the coil, away from the radial inner wall.

7. A coil wound on a bobbin according to claim 5, wherein the first portion of the central section defines the first recess away from the radially inward side wall, and the first recess is configured to receive the end portion of the coil.

8. A coil wound on a bobbin according to claim 7, wherein the second portion of the central section defines a second recess away from the radially inward side wall, and the second recess is configured to receive the starting portion of the coil.

9. A coil wound on a bobbin according to claim 5, wherein the first portion of the central section defines the first recess, away from the radially inward side wall, and the first recess is configured to receive the starting portion of the coil.

10. The aforementioned terminal connector is The main body defines the central cavity, The post extending from the outer surface of the main body of the terminal connector Includes, A coil wound on a bobbin according to claim 1 or 2, wherein one of the starting portion and the ending portion of the coil is wound around the post.

11. The coil wound on a bobbin according to claim 10, further comprising a locking tab extending from the outer surface of the body of the terminal connector, wherein the post is radially aligned with the locking tab.

12. The locking tab has a triangular cross-section and includes an edge extending radially along the outer surface of the body of the terminal connector, an edge extending axially away from the outer surface of the body of the terminal connector, and an inclined edge extending between the radially extending edge and the axially extending edge, as described in claim 11.

13. The coil wound on a bobbin according to claim 10, wherein the terminal connector further includes a second post extending from the outer surface of the body of the terminal connector, and the other of the starting portion and the ending portion of the coil is wound around the second post.

14. A coil wound on a bobbin according to claim 13, wherein the terminal connector includes third and fourth posts extending from the outer surface of the body of the terminal connector, the starting portion of the coil is wound around two of the first, second, third and fourth posts, and the ending portion of the coil is wound around two other posts.

15. The coil wound on a bobbin according to claim 1 or 2, wherein the axial thickness of the first end flange varies adjacent to the radial inner wall, the radial outer wall, and first and second side walls extending radially between the radial inner wall and the radial outer wall, defining a first recess on the outer side of the first end flange, and the radial outer wall includes a first opening extending through it and communicating with the first recess.

16. The coil wound on a bobbin according to claim 1 or 2, further comprising a rotation-preventing member extending from the cylindrical body, one of the first end flange and the second end flange, and configured to engage with the field shell of the electromagnetic coupler.

17. A coil wound on a bobbin according to claim 1 or 2, further comprising means for preventing the bobbin from rotating relative to the field shell of the electromagnetic coupling machine.

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