Bobbin wound coil for electromagnetic coupler

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 opposite axial ends of the cylindrical body and extending radially outward from the opposite axial ends, and terminal connectors disposed at opposite axial ends of the cylindrical body and extending radially outward from the opposite axial ends. Each end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, and a terminal connector is located on the outer side of one of the end flanges. In various embodiments, one or more of the cylindrical body, the end flange, and / or the terminal connector are formed to avoid the need to generally form an external projection on the end flange to promote winding of the coil, enabling fluid to exit from a pocket formed outside of the end flange, and to prevent fluid leakage. Means are provided to tension and / or secure the ends of the coils during winding, and / or to prevent rotation of the bobbin relative to the field shell of the coupler.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application claims the benefit of and priority under 35 USC §119 to U.S. Provisional Patent Application No. 63 / 338,058, filed on May 4, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to electromagnetic couplings. In particular, the present invention relates to an improved bobbin wound coil for electromagnetic couplings. Background Art

[0004] A conventional electromagnetic coupler includes an armature on which a force is applied to move the armature between an engagement position or a disengagement position with a rotor or a friction disk so as to transfer a rotational or braking torque between one body coupled to the armature and another body coupled to the rotor or the friction disk. When an electromagnet disposed on one side of the armature is energized to create an electromagnetic circuit between the electromagnet and the armature and to pull the armature toward the electromagnet and toward or away from the rotor or the friction disk, the armature moves to at least one of the engagement and disengagement positions by the electromagnetic force generated. The electromagnet includes a field housing and a conductor, the field housing being made of a material having a relatively low magnetic resistance, and current is supplied to the conductor to excite the electromagnet and to create an electromagnetic circuit by causing flux to flow within and between the field housing and the armature. The conductor typically includes a coil wound around a bobbin mounted on or within the field housing and connected to an external power source.

[0005] Conventional bobbin winding coils have one or more disadvantages. Conventional bobbins include: a cylindrical body; a flange 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 adjacent to the radial outer edge of the end flange. When the coil is wound on the bobbin, the beginning of the coil usually passes through the terminal connector and the end flange near the radial outer edge of the end flange, and then moves 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, the end portion of the coil again passes through the end flange and the terminal connector near the radial outer edge of the end flange. When the coil is wound around the body of the bobbin, the coil must pass over the radially inwardly extending section of the beginning of the coil, and a protrusion protruding outward is usually formed on the outer side of one of the flanges to accommodate this winding mode, thereby causing manufacturing and packaging problems. Conventional bobbins also often lack adequate mechanisms and / or require additional mechanisms to adequately tension the beginning and end portions of the coil during winding of the coil and / or to secure the beginning and end portions of the coil within the terminal connector during winding. In some conventional bobbins, one or more flanges in the bobbin may also form recesses on the outside of the flanges to balance the goal of strengthening the end flanges 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 mounted thereon) also rotate relative to the field housing on which the bobbin is mounted due to torque transfer during operation of the coupler.

[0006] The inventors herein have recognized that there is a need for a bobbin wound coil for an electromagnetic coupler that minimizes and / or eliminates one or more of the above-mentioned disadvantages. Summary of the invention

[0007] The present invention relates to an electromagnetic coupler and more particularly to an improved bobbin wound coil for an electromagnetic coupler.

[0008] According to one embodiment, a bobbin wound coil for an electromagnetic coupler includes a bobbin, which includes a cylindrical body arranged around a central axis. The bobbin also includes a first end flange and a second end flange, the first end flange is arranged at a first axial end of the cylindrical body and extends radially outward from the first axial end, the first end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, the second end flange is arranged at a second axial end of the cylindrical body and extends radially outward from the second axial end, and the second end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin also includes a terminal connector located on the outer side of the first end flange. The bobbin wound coil also includes a coil, the coil having a first opening extending through the terminal connector and a first opening in the first end flange The start portion and an end portion extending through the second opening in the terminal connector and the second opening in the first end flange. The second opening in the terminal connector is located in front of the first opening in the terminal connector in the first circumferential direction. The second opening in the first end flange is located behind the first opening in the first end flange in the first circumferential direction. The start portion includes a first section extending from a first opening in the terminal connector to a first opening in the first end flange, and the end portion includes a first section extending from a second opening in the terminal connector to a second opening in the first end flange. The first section of the end portion of the coil intersects the first section of the start portion of the coil.

[0009] According to another embodiment, a bobbin wound coil for an electromagnetic coupler includes a bobbin, which includes a cylindrical body arranged around a central axis. The bobbin also includes a first end flange and a second end flange, the first end flange is arranged at a first axial end of the cylindrical body and extends radially outward from the first axial end, the first end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, the second end flange is arranged at a second axial end of the cylindrical body and extends radially outward from the second axial end, and the second end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin also includes a terminal connector located on the outer side of the first end flange. The terminal connector includes a body defining a central cavity, and includes an axially spaced inner wall and an outer wall, a circumferentially spaced first side wall and a second side wall extending between the inner wall and the outer wall, and a radially inner side wall extending between the inner wall and the outer wall. The coil includes a start portion, an end portion, and a center portion, the start portion extending through a first opening in each of the inner wall and the outer wall of the body of the terminal connector, the end portion extending through a second opening in each of the inner wall and the outer wall of the body of the terminal connector, and the center portion extending between the start portion and the end portion and winding around the cylindrical body. The inner wall of the body of the terminal connector includes a first circumferential end segment and a second circumferential end segment and a center segment, the center segment being disposed between the first circumferential end segment and the second circumferential end segment and being separated from the first circumferential end segment and the second circumferential end segment by a corresponding opening in the first opening and the second opening in the inner wall. A portion of one of the first circumferential end segment, the second circumferential end segment, and the center segment is spaced apart from the radially inner sidewall to define a first recess, the first recess being configured to receive one of the start portion and the end portion of the coil.

[0010] According to another embodiment, a bobbin-wound coil for an electromagnetic coupler includes a bobbin, which includes a cylindrical body arranged around a central axis. The bobbin also includes a first end flange and a second end flange, the first end flange is arranged at a first axial end of the cylindrical body and extends radially outward from the first axial end, the first end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, the second end flange is arranged at a second axial end of the cylindrical body and extends radially outward from the second axial end, and the second end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin also 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 column extending from the outer surface of the body of the terminal connector. The bobbin also includes a coil, which has a starting portion extending through the body of the terminal connector and the first end flange, an end portion extending through the body of the terminal connector and the first end flange, and a central portion extending between the starting portion and the end portion and wound around the cylindrical body of the bobbin. One of the starting portion and the end portion of the coil is wound around the column.

[0011] According to one embodiment, a bobbin for a coil of an electromagnetic coupler includes a cylindrical body arranged around a central axis. The bobbin also includes a first end flange and a second end flange, the first end flange being arranged at a first axial end of the cylindrical body and extending radially outward from the first axial end, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, the second end flange being arranged at a second axial end of the cylindrical body and extending radially outward from the second axial end, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The axial thickness of the first end flange varies to define a recess in the outer side of the first end flange, the recess being defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall. The radial outer wall includes an opening extending through the radial outer wall and communicating with the recess.

[0012] A bobbin for a coil for an electromagnetic coupler according to another embodiment includes a cylindrical body arranged around a central axis. The bobbin also includes a first end flange and a second end flange, the first end flange being arranged at a first axial end of the cylindrical body and extending radially outward from the first axial end, the first end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, the second end flange being arranged at a second axial end of the cylindrical body and extending radially outward from the second axial end, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin also includes an anti-rotation 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.

[0013] According to another embodiment, a bobbin for a coil of an electromagnetic coupler includes a cylindrical body arranged around a central axis. The bobbin also includes a first end flange and a second end flange, the first end flange is arranged at a first axial end of the cylindrical body and extends radially outward from the first axial end, the first end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, the second end flange is arranged at a second axial end of the cylindrical body and extends radially outward from the second axial end, the second end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin also includes a device for preventing the bobbin from rotating relative to the field shell of the electromagnetic coupler.

[0014] A method for forming a bobbin wound coil for an electromagnetic coupler according to one embodiment includes providing a bobbin including a cylindrical body arranged around a central axis. The bobbin also includes a first end flange, which is arranged at a first axial end of the cylindrical body and extends radially outward from the first axial end, and the first end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin also includes a second end flange, which is arranged at a second axial end of the cylindrical body and extends radially outward from the second axial end, and the second end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body. The bobbin also includes a terminal connector located on the outer side of the first end flange. The method also 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 and a second opening in the terminal connector, the second opening in the first end flange being located behind the first opening in the first end flange in a first circumferential direction, and the second opening in the terminal connector being located in front of the first opening in the terminal connector in the first circumferential direction, so 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 intersects with a first section of the starting portion of the coil extending from the first opening in the terminal connector to the first opening in the first end flange.

[0015] According to another embodiment, a method for forming a bobbin wound coil for an electromagnetic coupler includes providing a bobbin. The bobbin includes a cylindrical body arranged around a central axis; a first end flange, the first end flange is arranged at a first axial end of the cylindrical body and extends radially outward from the first axial end, the first end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange, the second end flange is arranged at a second axial end of the cylindrical body and extends radially outward from the second axial end, the second end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a terminal connector located on the outer side of the first end flange. The terminal connector includes a body defining a central cavity, and includes an axially spaced inner wall and an outer wall, a circumferentially spaced first side wall and a second side wall extending between the inner wall and the outer wall, and a radially inner side wall extending between the inner wall and the outer wall. The inner wall of the body of the terminal connector includes a first circumferential end section and a second circumferential end section and a central section, wherein the central section is disposed between the first circumferential end section and the second circumferential end section and is separated from the first circumferential end section and the second circumferential end section by a first opening and a second opening in the inner wall. A portion of one of the first circumferential end section, the second circumferential end section, and the central section is spaced apart from the radially inner sidewall to define a first recess. The method also includes inserting a beginning portion of the coil through the first opening in the inner wall of the terminal connector, winding the coil around the cylindrical body, and inserting an end portion of the coil through the second opening in the inner wall of the terminal connector, wherein one of the beginning portion and the end portion of the coil extends through the first recess.

[0016] According to another embodiment, a method for forming a bobbin wound coil for an electromagnetic coupler includes: providing a bobbin. The bobbin includes a cylindrical body arranged around a central axis; a first end flange, the first end flange is arranged at a first axial end of the cylindrical body and extends radially outward from the first axial end, the first end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; a second end flange, the second end flange is arranged at a second axial end of the cylindrical body and extends radially outward from the second axial end, the second end flange defines an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, and a terminal connector located on the outer side of the first end flange. The terminal connector includes a body defining a central cavity and a first column extending from an outer surface of the body of the terminal connector. The method also includes inserting a starting portion of the coil through the terminal connector and the first end flange, winding the coil around the cylindrical body, and inserting an end portion of the coil through the first end flange and the terminal connector. The method also includes winding one of the starting portion and the end portion of the coil around the column.

[0017] The bobbin wound coil according to the teachings herein represents an improvement over conventional bobbin wound coils used in electromagnet couplers. In particular, the coil of the bobbin wound coil is wound in a manner that is configured to eliminate any need for outwardly projecting protrusions on the outside of the end flange to accommodate common wiring patterns, thereby improving manufacturability and packaging.

[0018] The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from a reading of the following description and claims, and from a review of the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a cross-sectional view of one embodiment of an electromagnetic coupler that may include a bobbin wound coil according to the teachings herein.

[0020] Figure 2-Figure 4 is a perspective view of one embodiment of a bobbin wound coil according to the teachings herein.

[0021] Figure 5 is a perspective view of another embodiment of a bobbin wound coil according to the teachings herein.

[0022] Figure 6 yes Figure 2-Figure 4 Another perspective view of the bobbin-wound coil.

[0023] Figure 7 yes Figure 2-Figure 4 and Figure 6 An enlarged perspective view of a portion of a bobbin wound coil.

[0024] Figure 8 is a perspective view of another embodiment of a bobbin wound coil according to the teachings herein.

[0025] Figure 9-10 yes Figure 2-Figure 4 and Figure 6 An enlarged perspective view of a portion of a bobbin wound coil. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Referring now to the drawings, wherein like reference numerals are used to refer to like parts throughout the various views, Figure 1An electromagnetic coupler 10 including a bobbin-wound coil is shown. In the illustrated embodiment, the coupler 10 provides a braking torque to a rotating body (such as a shaft, gear, pulley, blade, etc.) to slow down or stop the rotation of the rotating body. One of ordinary skill in the art will appreciate that the device 10 can be used in a variety of industrial and other applications where braking is required. Although the coupler 10 is used as a brake in the illustrated embodiment, it should be understood that the coil-wound bobbin embodiments disclosed herein can also be used on an electromagnetic coupler configured to act as a clutch that transfers torque from a rotating body to a rotating 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.

[0028] A rotor 12 is provided to transmit braking 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 an axis of rotation 24 and centered on the axis of rotation 24. The rotor 12 is coupled to a shaft (not shown) and configured to rotate with the shaft (not shown) about the axis 24 and may be rotatably coupled to the shaft in various ways that allow the rotor 12 to move axially relative to the shaft to achieve proper operation of the device 10 and to allow for wear, vibration, runout or thermal expansion. For example, the radial inner surface of the rotor 12 and the radial outer surface of the shaft may have complementary torque transmission shapes, such as splines (as shown in the illustrated embodiment), keys and keyways, single or double D-shaped or hexagonal shapes. The rotor 12 includes friction surfaces on opposite sides 26, 28 that are configured to engage the brake plate 14 and the armature 16, respectively, during application or engagement of the brake.

[0029] The brake plate 14 is configured to engage the rotor 12 during the application of the brake to transmit the braking torque to the rotor 12. The brake plate 14 provides a reaction surface against which the armature 16 presses the rotor 12 during the application of the brake. The brake plate 14 can be made of conventional metal or plastic, and in some embodiments can be made of steel (including stainless steel). The brake plate 14 is disposed on a side 26 of the rotor 12. The brake plate 14 can also be disposed around the axis 24 and centered on the axis 24. The brake plate 14 is fixed to prevent rotation and can be coupled to the electromagnet 22 using a plurality of axially extending fasteners (such as bolts, pins, screws or the like).

[0030] The armature 16 is also configured to engage the rotor 12 during the application of the brake to transmit the braking torque to the rotor 12. The armature 16 may be made of a metal or metal alloy or other material with relatively low magnetic resistance (such as iron or steel). The armature 16 is disposed on a side 28 of the rotor 12. The armature 16 may also be disposed around the axis 24 and centered on the axis 24. The armature 16 is fixed to prevent rotation, but may move axially toward and away from the rotor 12 and the brake plate 14 to allow engagement and disengagement of the brake. The armature 16 may include a plurality of holes extending through the armature 16 or a plurality of recesses in the radial outer surface of the armature 16, the plurality of holes or the plurality of recesses being configured to allow fasteners connecting the brake plate 12 and the electromagnet 22 to pass through the armature 16. In this way, the fasteners limit or prevent the armature 16 from rotating around the axis 24, but allow the armature 16 to move along the axis 24.

[0031] The spring 18 provides a means for biasing the armature 16 in one direction along the axis 24 toward the rotor 12 and the brake plate 14 to engage the brake. The spring 18 may be disposed between the electromagnet 22 and the armature 16. It should be appreciated that the coupler 10 may include a single annular spring 18 or a plurality of springs 18 disposed in an annular array about the axis 24. In the latter case, the springs 18 may be equally spaced circumferentially about the axis 24.

[0032] The spacer 20 is provided to position and orient the brake plate 14 and the electromagnet 22 relative to each other and define an enclosed space containing the rotor 12 and the armature 16 together with the brake plate 14 and the electromagnet 22. The spacer 22 can be made of conventional materials including metals (such as aluminum) or plastics that are non-magnetic or have relatively high magnetic resistance. The spacer 22 can include a plurality of circumferentially evenly spaced, radially inwardly extending flanges that define fastener holes aligned with corresponding holes 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 so as to couple the brake plate 14, the spacer 20, and the electromagnet 22 together. After assembly, the spacer 20 is disposed radially outside 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.

[0033] The electromagnet 22 provides a means for pushing the armature 16 away from the rotor 12 and the brake plate 14 in opposite directions along the axis 24 to disengage the brake. The electromagnet 22 may include a field housing 30 and a conductor in the form of a bobbin-wound coil 32. The field housing 30 houses the bobbin-wound coil 32 and may also provide structural support and orient other components of the device 10, including the brake plate 14 and the spring 18. The field housing 30 may be annular and disposed about and centered on the axis 24, and may be disposed on a side of the armature 16 opposite the rotor 12. The field housing 30 may be made of a material having a relatively low magnetic resistance, such as a ferromagnetic material. The field housing 30 may define a radially extending end wall 34 and an axially extending, radially aligned inner wall 36 and outer wall 38 extending axially from the end wall 34 toward the armature 16. The outer wall 38 may define one or more closed holes 40 configured to receive one end of each spring 18. The outer wall 38 may also define one or more closed holes (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 housing 30 between the walls 36, 38. Current supplied to the coil creates an electromagnetic circuit including the armature 16 and the field housing 30. The electromagnetic circuit, under the force of the spring 18, pushes the armature 16 toward the field housing 30 and away from the rotor 12 to disengage the brake.

[0034] Reference now Figure 2-Figure 4 , an embodiment of a bobbin winding coil 32 according to the present teaching will be described. The bobbin winding coil 32 includes a bobbin 42 and a reference Figure 9-10 Coil 44.

[0035] Reference again Figure 2-Figure 4 , a bobbin 42 is provided to position and orient the coil 44. The bobbin 42 may be made of conventional plastic or other material having a relatively high magnetic resistance. The bobbin may include a body 46, end flanges 48, 50 and a terminal connector 52.

[0036] The body 46 is cylindrical in shape and may be disposed about and centered on a central axis, such as the axis 24 in the electromagnetic coupler 10. The body 46 defines a central bore configured to receive a portion of the field shell 30. Figure 1 , the radial inner surface of the body 46 can engage the inner wall 36 of the field shell 30. The radial outer surface of the body 46 is configured to support the coil 44 once the coil 44 is wound onto the bobbin 42. Figure 2-Figure 4 In the illustrated embodiment, the body 46 is cylindrical in shape along its entire axial length. Figure 5In an alternative embodiment, the bobbin wound coil 54 may include a means for preventing rotation of the bobbin wound coil 54 relative to the field housing 30, such as an anti-rotation member in the form of one or more flats 56 extending from the body 58 of the bobbin. The flats 56 may be formed in the radially inner surface of the body 58 of the bobbin 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 formed in the wall 36 of the field housing 30. In this way, rotation of the bobbin wound coil 54 relative to the field housing 30 caused by forces during torque transfer in the coupler 10 is prevented.

[0037] Reference again Figure 2-Figure 4 The end flanges 48, 50 together with the body 46 define a space configured to receive, position and hold the coil 44. The flanges 48, 50 are disposed at opposite axial ends of the body 46 and extend radially outward from the axial ends. Figure 3 Each flange 48, 50 defines an inner side 60, 62, respectively, facing toward 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.

[0038] The shape and axial thickness of the end flange 48 can vary. In particular, the shape and axial thickness of the end flange 48 can vary to accommodate the passage of the coil 44 from the body 46 to the terminal connector 52 and the placement of the beginning of the coil 44. Now referring to Figure 6 , the flange 48 defines a pair of openings 68, 70 extending through the flange 48 from the outer side 64 of the flange 48 to the inner side 60 of the flange 48, and the beginning and end portions of the coil 44 can extend through the pair of openings 68, 70, respectively. A circumferential segment 72 of the flange 48 adjacent to the opening 68 has a reduced axial thickness relative to other circumferential segments of the flange 48, so that the distance d1 from the inner side 60 of the segment 72 of the end flange 48 to the inner side 62 of the end flange 50 is greater than the distance d2 from the inner side 60 of the other circumferential segments of the end flange 48 to the inner side 62 of the end flange 50. The segment 72 is configured to receive a radially extending segment of the beginning portion of the coil 44 extending along the inner side 60 of the segment 72 of the end flange 48 between the opening 68 and the radial outer surface of the body 46, so that the segment of the beginning portion of the coil 44 is not interfered with when the coil 44 is subsequently wound around the body 46.

[0039] Reference again Figure 2, the axial thickness of the flange 48 may be further varied to radially define one or more recesses 74 in the outer side 64 of the end flange 48 along inner and outer hubs or walls 76 and 78 extending circumferentially about the radially inner and outer edges of the flange 48 and a plurality of spokes or sidewalls 80 extending between the walls 76, 78 and defining the recesses 74. The walls 76, 78, 80 provide added strength 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. Referring now to Figure 7 , each recess 74 on the outer side 64 of the flange 48 is defined by opposing inner and outer walls 76, 78 and a pair of adjacent opposing side walls 80. Depending on the application and operating environment for the coupler 10, the bobbin wound coil 32 may be exposed to fluid or other debris that may potentially collect in the recess 74. According to one aspect of the present 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 the surface defining the bottom of the recess 74 and the surface of the wall 78 to facilitate the outflow of fluid and debris.

[0040] Reference again Figure 2-Figure 4 , the end flange 50 may have a uniform or substantially uniform axial thickness. However, reference is now made to Figure 8 In an alternative embodiment, the bobbin wound coil 84 may include a means for preventing rotation of the bobbin wound coil 84 relative to the field housing 30, such as an anti-rotation member in the form of one or more lugs 86 extending axially from the flange 88. The lugs 86 may be formed in the outer side of the flange 88 and configured to engage corresponding recesses formed in the wall 34 of the field housing 30. In this manner, rotation of the bobbin wound coil 84 relative to the field housing 30 caused by forces during torque transfer in the coupler 10 is prevented. The lugs 86 may also facilitate proper orientation of the bobbin wound coil 84 relative to the field housing 30 during assembly of the coupler 10.

[0041] Reference again Figure 2-Figure 4 , the terminal connector 52 provides a means for connecting the coil 44 to an external power source. The connector 52 can be formed as an integral (single-piece) structure with the body 46 and the flanges 48, 50. The connector 52 can be located on the outer side 64 of the flange 48 near the radial outer edge of the flange 48. Now referring to Fig. 9 The connector 52 includes a body 90 including an axially spaced inner wall 92 and an outer wall 94, circumferentially spaced side walls 96, 98 extending between the inner wall 92 and the outer wall 94, and a reference Figure 4 A radially inner sidewall 100 extends between the inner wall 92 and the outer wall 94. Referring again to Fig. 9, the body 96 defines a central cavity 102 bounded by walls 92, 94, 96, 98, 100, which is configured to receive a pair of terminal pins 104, 106 supported within the cavity 102 to contact portions of the coil 44 and, after the coupler 10 is assembled, to contact matching electrical contacts in corresponding terminal connectors of an external power source (not shown) received within the cavity 102.

[0042] Reference again Figure 3 , the outer wall 94 may include one or more locking tabs 108 extending from the outer surface of the wall 94 of the body 90 for fixing the connection between the terminal connector 52 and the terminal connector for the external power supply. 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 cross-section of the tab 108 may be generally triangular, and specifically, include a right-angled triangle, with the tab 108 having a radially extending edge 110 along the surface of the wall 94, an axially extending edge 112 extending from the wall 94, and an inclined edge 114 or ramp extending between the edges 110, 112. When the terminal connector for the external power supply moves toward the terminal connector 52, the tab 108 causes the corresponding locking element on the terminal connector for the external power supply to deflect from the standard position and away from the wall 94 of the terminal connector 52 as it moves along the edge 114 of the tab 108. Once the locking element reaches the end of edge 114 adjacent to edge 112, the locking element will return to its normal position and move toward wall 94 of terminal connector 52 so that tab 108 will prevent the terminal connector for the external power supply from moving in a direction away from terminal connector 52 and disconnection between the two connectors.

[0043] Reference again Figure 2 According to another aspect of the teachings herein, the outer wall 100 can include a plurality of posts 116, 118, 120, 122 extending from the outer surface of the wall 94 of the body 90 adjacent the 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 the coupler 10, and at least one post (post 120 in the illustrated embodiment) can 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 winding of the coil 44 begins, 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 to provide tension on the coil 44 as the coil 44 is wound through the connector 52 and the flange 48 and onto the body 46 of the bobbin 42. Similarly, at the end of winding the coil 44, the end portion of the coil 44 leaves the cavity 102 of the terminal connector 52 and is then wound around the posts 120, 122 to provide 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 poles 116, 118 and 120, 122 are used to wind the beginning and end portions of coil 44, respectively, in the illustrated embodiment, it should be understood that the number of poles may vary and the beginning and end portions of coil 44 may each be wound around a single pole, for example.

[0044] The inner wall 92 and the outer wall 94 of the terminal connector 52 each include a pair of openings 124, 126 and 128, 130 in the form of generally radially extending slots, which are configured to receive the beginning and end portions of the coil 44 during winding of the coil 44 onto the bobbin 42. The openings 124, 126 and 128, 130 in the walls 92, 94 extend from the radial outer edge of each wall 92, 94 to a position adjacent to the radial inner edge of each wall 92, 94 and adjacent to the radial inner sidewall 100. The openings 124, 128 can be aligned with each other. The openings 126, 130 can also be aligned with each other. The openings 124, 126 and 128, 130 effectively divide each of the inner wall 92 and the outer wall 94 into three separate sections. In particular, the openings 124, 126 divide the wall 92 into a pair of circumferential end segments 132, 134 and a center segment 136 that is disposed between and separated from the circumferential end segments 132, 134 by the openings 124, 126. Likewise, the openings 128, 130 divide the wall 94 into a pair of circumferential end segments 138, 140 and a center segment 142 that is disposed between and separated from the circumferential end segments 138, 140 by the openings 118, 130. According to another aspect of the teachings herein, a portion of one or more of the segments 132, 134, 136 of the inner wall 92 can be spaced apart from the side wall 100 to define a recess 144 configured to receive a portion of the coil 44. These recesses 144 help to properly place and retain the beginning and / or end portions of the coil 44 within the cavity 102 of the terminal connector 52, and in particular, help to properly place and align the coil 44 and the upper and lower saddles of the coil 44 formed in the connector 52 on either side of the terminal pins 104, 106 when the winding nozzle used to dispense the coil 44 and wind the coil 44 onto the bobbin 42 leaves the connector 52, thereby ensuring proper tension in the coil 44 and ultimately helping to properly connect the terminals 104, 106 to the beginning and end portions of the coil 44. In the illustrated embodiment, the recess 144 is formed in a portion of the section 136 of the inner wall 92 adjacent the opening 126 and receives the end portion of the coil 44. However, it should be understood that a similar recess may be formed in a portion of the section 136 adjacent to the opening 124 to receive the beginning portion of the coil 44, or a similar recess may be formed in either of the end sections 132, 134 adjacent to the openings 124, 126 to receive the beginning portion or the end portion of the coil 44, respectively.

[0045] Reference again Figure 9-10, a coil 44 is provided to conduct current provided from an external power source and establish an electromagnetic circuit between the armature 16 and the field housing 30, which attracts the armature 16 toward the field housing 30 to release 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. Reference Fig.10 , winding of the bobbin 42 may begin by winding the beginning portion 146 of the coil 44 around the posts 116, 118. Fig. 9 , the beginning portion 146 of the wrap 44 is then fed through the opening 128 in the outer wall 94 of the terminal connector 52 and the opening 124 in the inner wall 92 of the terminal connector 52. As described above, the portion 146 of the wrap 44 may be positioned within a recess 144 formed in the section 132 or section 136 of the inner wall 92 adjacent to the opening 124, if such a recess 144 is provided. Referring again to Figure 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 segment 148 of a portion 146 of the coil 44 extends from the opening 124 in the inner wall 92 of the terminal connector 52 in a circumferential direction through 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 so that another segment 150 of the beginning portion 146 of the coil 44 extends radially inward from the segment 148. Referring again to Figure 6 , the section 148 extends toward the body 46 along the inner side of the circumferential section 72 of the end flange 48. Then, the central portion of the coil 44 extending between the start portion and the end portion of the coil 44 is repeatedly wound around the body 46 until a predetermined amount of the coil 44 is wound around the body 46. Then, the end portion 152 (see Fig.10 ) is fed through the opening 70 in the end flange 48 and referenced to Fig. 9 , fed through the opening 126 in the inner wall 92 of the terminal connector 52. Fig.10According to the present teachings, the end portion 152 of the coil 44 is positioned so that a segment 154 of the end portion 152 of the coil 44 extends from the opening 126 in the inner wall 92 of the terminal connector 52 through the opening 124 in the inner wall 92 of the terminal connector 52 in a circumferential direction to the opening 70 in the end flange 48, so that the segment 154 of the end portion 152 of the coil 44 intersects the segment 148 of the beginning portion 146 of the coil 44. This placement and arrangement of the portions 146, 152 of the coil 44 inside the terminal connector 52 enables the segment 150 of the beginning portion 146 of the coil 44 to be placed in a position that does not interfere with subsequent winding of the coil 44 around the body 46, thereby eliminating any need for an outwardly protruding protrusion on the outside of the end flange 48 to accommodate the coil 44 and improving the manufacturability and packaging of the bobbin wound coil 32. When passing through the opening 126 in the inner wall 92 of the terminal connector 52, the end portion 152 may be located 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 sections 134 of the inner wall 92). The end portion 152 is then passed through the opening 130 in the outer wall 94 and wrapped around the posts 120, 122 before cutting the coil.

[0046] The bobbin-wound coil 32 according to the teachings herein represents an improvement over conventional bobbin-wound coils used in electromagnet coupling. In particular, in one embodiment, the bobbin-wound coil 32 is configured to eliminate any need for outwardly protruding protrusions on the outside of the end flange 48 to accommodate the usual wiring pattern, thereby improving manufacturability and packaging. In other embodiments, the bobbin-wound coil 32 is configured to facilitate tensioning of the beginning and / or end portions 146, 152 of the coil 44 during winding of the coil 44 and / or to secure the beginning and / or end portions 146, 152 of the coil 44 within the terminal connector 52 of the bobbin 42. In another embodiment, the bobbin 42 is configured to prevent liquid or debris from accumulating in the recess 74 formed on the outside 64 of the end flange 48, so as to balance competing goals while strengthening the end flange 48 while reducing weight and material costs. In other embodiments 54 or 84, the bobbin is also configured to prevent relative rotation of the bobbin and the field shell 30 in the electromagnetic coupler 10.

[0047] The additional claims of the present invention are as follows:

[0048] Statement 1. 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 from the first axial end, 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 from the second axial end, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a coil having a start portion and an end portion, the start portion extending through a terminal connector The first opening and the first opening in the first end flange, with an end portion extending through the 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 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 includes a first section extending from the first opening in the terminal connector to the first opening in the first end flange, and the end portion 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 end portion of the coil intersects with the first section of the starting portion of the coil.

[0049] Statement 2. The bobbin wound coil of statement 1, wherein a first section of a beginning portion of the coil extends beyond the second opening in the terminal connector, and a first section of an end portion of the coil extends beyond the first opening in the terminal connector.

[0050] Statement 3. A bobbin wound coil according to any one of Statements 1-2, wherein the first end flange includes a first circumferential segment and a second circumferential segment having different axial thicknesses, so 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 segment 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 segment of the first end flange, and a starting portion of the coil includes a second segment, and the second segment extends radially inward from the first segment of the starting portion of the coil along the inner side of the first end flange in the first circumferential segment of the first end flange.

[0051] Statement 4. The bobbin wound coil of statement 3, wherein a second section of the beginning portion of the coil extends radially inwardly from a first opening in the first end flange of the bobbin along an inner side of the first end flange in a first circumferential section of the first end flange to the cylindrical body of the bobbin.

[0052] Statement 5. A bobbin wound coil according to any one of statements 1-4, wherein the axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

[0053] Statement 6. The bobbin wound coil of any one of statements 1-5, wherein the terminal connector comprises: a body defining a central cavity; and a post extending from an outer surface of the body of the terminal connector; and wherein one of the beginning portion and the end portion of the coil is wound around the post.

[0054] 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, and wherein the post is radially aligned with the locking tab.

[0055] Statement 8. A bobbin wound coil according to any one of statements 1-7, wherein the terminal connector includes a body that defines a central cavity, and the body includes axially spaced inner and outer walls, circumferentially spaced first and second 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 a first circumferential end segment and a second circumferential end segment and a center segment, the center segment is disposed between the first circumferential end segment and the second circumferential end segment and is separated from the first circumferential end segment and the second circumferential end segment by corresponding openings in the first and second openings in the terminal connector, and a portion of one of the first circumferential end segment, the second circumferential end segment and the center segment is spaced from the radially inner side wall to define a first recess, the first recess being configured to receive one of a starting portion and an end portion of the coil.

[0056] Statement 9. The bobbin wound coil of any one of statements 1 to 8, further comprising an anti-rotation 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.

[0057] Statement 10. The bobbin wound coil of any of statements 1-8, further comprising means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0058] Statement 11. A method of forming a bobbin wound coil for an electromagnetic coupler, comprising: providing a bobbin, the bobbin including a cylindrical body disposed about a central axis; a first end flange, the first end flange disposed at a first axial end of the cylindrical body and extending radially outward from the first axial end, 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, the second end flange disposed at a second axial end of the cylindrical body and extending radially outward from the second axial end, 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, the terminal connector being located on an outer side of the first end flange; and, attaching a starting portion of the coil to the end of the coil. The coil is wound around the cylindrical body; and the end portion of the coil is inserted through a second opening in the first end flange (the second opening in the first end flange is located behind the first opening in the first end flange in the first circumferential direction) and a second opening in the terminal connector (the second opening in the terminal connector is located in front of the first opening in the terminal connector in the first circumferential direction), so 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 intersects with a first section of the starting portion of the coil extending from the first opening in the terminal connector to the first opening in the first end flange.

[0059] Statement 12. The method of forming a bobbin wound coil for an electromagnetic coupler according to statement 11, wherein a first section of a beginning portion of the coil extends through a second opening in the terminal connector and a first section of an end portion of the coil extends through a first opening in the terminal connector.

[0060] Statement 13. A method for forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 11-12, wherein the first end flange includes a first circumferential segment and a second circumferential segment having different axial thicknesses, so 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 segment 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 segment of the first end flange, the method also including placing a second segment of a starting portion of the coil, the second segment of the starting portion of the coil extending from the first segment of the starting portion of the coil along the inner side of the first end flange in the first circumferential segment of the first end flange.

[0061] Statement 14. A method for forming a bobbin wound coil for an electromagnetic coupler according to statement 13, wherein placing the second section of the starting portion of the coil includes arranging the second section of the starting portion of the coil so that the second section of the starting portion of the coil extends radially inward from a first opening in the first end flange of the bobbin along the inner side of the first end flange in a first circumferential segment of the first end flange to the cylindrical body of the bobbin.

[0062] Statement 15. A method for forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 11-14, wherein the axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

[0063] Statement 16. A method for forming a bobbin wound coil for an electromagnetic coupler according to 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 a beginning portion and an end portion of the coil around the post.

[0064] Statement 17. The method of forming a bobbin wound coil for an electromagnetic coupler of statement 16, wherein the terminal connector includes a locking tab extending from an outer surface of a body of the terminal connector, and wherein the post is radially aligned with the locking tab.

[0065] Statement 18. A method for forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 11-17, wherein the terminal connector includes a body, the body defining a central cavity and including an axially spaced inner wall and an outer wall, a circumferentially spaced first side wall and a second side wall extending between the inner wall and the outer wall, and a radially inner side wall extending between the inner wall and the outer wall, the inner wall of the body of the terminal connector includes a first circumferential end segment and a second circumferential end segment and a center segment, the center segment is arranged between the first circumferential end segment and the second circumferential end segment and is separated from the first circumferential end segment and the second circumferential end segment by corresponding openings in the first opening and the second opening in the terminal connector, and a portion of one of the first circumferential end segment, the second circumferential end segment and the center segment is spaced from the radially inner side wall to define a first recess, the first recess being configured to receive a portion of one of a start portion and an end portion of the coil.

[0066] Statement 19. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 11-18, wherein the bobbin further comprises an anti-rotation 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.

[0067] Statement 20. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 11-18, wherein the bobbin further comprises means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0068] Statement 21. A bobbin wound coil for an electromagnetic coupler, comprising: a bobbin, 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 from the first axial end, 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 from the second axial end, 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 located on the outer side of the first end flange, the terminal connector including a body, the body defining a central cavity and including axially spaced inner and outer walls, circumferentially spaced first and second 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 having a starting portion extending through a first opening in each of the inner and outer walls of the body of the terminal connector, an end portion extending through a second opening in each of the outer and inner walls of the body of the terminal connector, and a center portion extending between the starting portion and the end portion and wound around the cylindrical body, wherein the inner wall of the body of the terminal connector includes a first circumferential end segment and a second circumferential end segment and a center segment, the center segment being disposed between the first circumferential end segment and the second circumferential end segment and being spaced apart from the first circumferential end segment and the second circumferential end segment by a corresponding one of the first and second openings in the inner wall, and a portion of one of the first circumferential end segment, the second circumferential end segment and the center segment being spaced apart from the radially inner sidewall to define a first recess configured to receive one of the starting and end portions of the coil.

[0069] Statement 22. The bobbin wound coil of statement 21, wherein the first circumferential end segment, the second circumferential end segment, and another portion of one of the center segments are spaced apart from the radial inner wall to define a second recess configured to receive the other of the start portion and the end portion of the coil.

[0070] Statement 23. The bobbin wound coil of any of statements 21-22, wherein a first portion of the center section is spaced apart from the radially inner sidewall to define a first recess, and wherein the first recess is configured to receive an end portion of the coil.

[0071] Statement 24. The bobbin wound coil of statement 23, wherein the second portion of the center section is spaced apart from the radially inner sidewall to define a second recess and the second recess is configured to receive a beginning portion of the coil.

[0072] Statement 25. The bobbin wound coil of any of statements 21-22, wherein a first portion of the center section is spaced apart from the radially inner sidewall to define a first recess, and wherein the first recess is configured to receive a beginning portion of the coil.

[0073] Statement 26. A bobbin wound coil according to any one of Statements 21-25, wherein a starting portion of the coil extends through a first opening in a first end flange, and an end 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 located in front of the first opening in the inner wall of the terminal connector in a first circumferential direction, and the second opening in the first end flange is located 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 end 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 end portion of the coil intersects with the first section of the starting portion of the coil.

[0074] Statement 27. A bobbin wound coil according to any one of Statements 21-26, wherein the axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

[0075] Statement 28. The bobbin wound coil of any of statements 21-27, wherein the terminal connector includes a post extending from an outer surface of a body of the terminal connector, and wherein one of a beginning portion and an end portion of the coil is wound around the post.

[0076] Statement 29. The bobbin wound coil of any of statements 21-28, further comprising an anti-rotation 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.

[0077] Statement 30. The bobbin wound coil of any of statements 21-28, further comprising means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0078] Statement 31. A method of forming a bobbin wound coil for an electromagnetic coupler, comprising: providing a bobbin, the bobbin comprising a cylindrical body disposed about a central axis; a first end flange, the first end flange disposed at a first axial end of the cylindrical body and extending radially outward from the first axial end, 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, the second end flange disposed at a second axial end of the cylindrical body and extending radially outward from the second axial end, 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 located on an outer side of the first end flange, the terminal connector comprising a body, the body defining a central cavity and comprising an axially spaced inner wall and an outer wall, a circumferentially spaced inner wall extending between the inner wall and the outer wall. The first side wall and the second side wall and the radial inner wall extending between the inner wall and the outer wall, the inner wall of the body of the terminal connector includes a first circumferential end segment and a second circumferential end segment and a center segment, the center segment is arranged between the first circumferential end segment and the second circumferential end segment and is separated from the first circumferential end segment and the second circumferential end segment by the first opening and the second opening in the inner wall, a portion of the first circumferential end segment, the second circumferential end segment and one of the center segments are spaced apart from the radial inner wall to define a first recess; inserting the starting portion of the coil through the first opening in the inner wall of the terminal connector; winding the coil around the cylindrical body; and inserting the end portion of the coil through the second opening in the inner wall of the terminal connector, wherein one of the starting portion and the end portion of the coil extends through the first recess.

[0079] Statement 32. A method for forming a bobbin wound coil for an electromagnetic coupler according to statement 31, wherein another portion of one of the first circumferential end segment, the second circumferential end segment, and the center segment is spaced apart from the radial inner wall to define a second recess, and the other of the start portion and the end portion of the coil extends through the second recess.

[0080] Statement 33. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 31-32, wherein a first portion of the center section is spaced apart from the radially inner sidewall to define a first recess, and an end portion of the coil extends through the first recess.

[0081] Statement 34. The method of forming a bobbin wound coil for an electromagnetic coupler of statement 33, wherein the second portion of the center section is spaced apart from the radially inner sidewall to define a second recess, and the beginning portion of the coil extends through the second recess.

[0082] Statement 35. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 31-32, wherein a first portion of the center section is spaced apart from the radially inner sidewall to define a first recess, and a beginning portion of the coil extends through the first recess.

[0083] Statement 36. A method for forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 31-35, the method comprising inserting a starting portion of the coil through a first opening in a first end flange, and inserting an end portion of the coil through a second opening in the first end flange, the second opening in the inner wall of the terminal connector being located in front of the first opening in the inner wall of the terminal connector in a first circumferential direction, and the second opening in the first end flange being located behind the first opening in the first end flange in the first circumferential direction, the starting portion of the coil comprising 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 end portion comprising 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, the first section of the end portion of the coil intersecting with the first section of the starting portion of the coil.

[0084] Statement 37. A method for forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 31-36, wherein the axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

[0085] Statement 38. A method of forming a bobbin wound coil for an electromagnetic coupler according to any 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 a beginning portion and an end portion of the coil around the post.

[0086] Statement 39. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 31-38, wherein the bobbin further comprises an anti-rotation 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.

[0087] Statement 40. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 31-38, wherein the bobbin further comprises means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0088] Statement 41. A bobbin-wound coil for an electromagnetic coupler, comprising: a bobbin, the bobbin including a cylindrical body arranged around a central axis; a first end flange, the first end flange being arranged at a first axial end of the cylindrical body and extending radially outward from the first axial end, 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, the second end flange being arranged at a second axial end of the cylindrical body and extending radially outward from the second axial end, 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 a first column extending from an outer surface of the body of the terminal connector; and a coil, the coil having a starting portion extending through the body of the terminal connector and the first end flange, an end portion extending through the body of the terminal connector and the first end flange, and a center portion extending between the starting portion and the end portion, and the center portion being wound around the cylindrical body of the bobbin, wherein one of the starting portion and the end portion of the coil is wound around the first column.

[0089] 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, and wherein the first post is radially aligned with the locking tab.

[0090] Statement 43. A wire bobbin winding coil according to statement 42, wherein the cross-section of the locking tab is triangular, and the locking tab includes a radially extending edge along the 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 an inclined edge extending between the radially extending edge and the axially extending edge.

[0091] Statement 44. The bobbin wound coil of any one of statements 41-43, wherein the terminal connector further comprises a second post extending from an outer surface of the body of the terminal connector, and the other of the start portion and the end portion of the coil is wound around the second post.

[0092] Statement 45. A wire bobbin wound coil according to statement 44, wherein the terminal connector includes a third column and a fourth column extending from the outer surface of the body of the terminal connector, a beginning portion of the coil is wound around two of the first column, the second column, the third column and the fourth column, and an end portion of the coil is wound around the other two of the first column, the second column, the third column and the fourth column.

[0093] Statement 46. A wire bobbin wound coil according to any one of Statements 41-45, wherein a starting portion of the coil extends through a first opening in a terminal connector and a first opening in a first end flange, and an end 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 being located in front of the first opening in the terminal connector in a first circumferential direction, and the second opening in the first end flange being located 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 end 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, the first section of the end portion of the coil intersecting with the first section of the starting portion of the coil.

[0094] Statement 47. A bobbin wound coil according to any one of Statements 41-46, wherein the body of the terminal connector includes axially spaced inner and outer walls, circumferentially spaced first and second side walls extending between the inner and outer walls, and a radially inner wall extending between the inner and outer walls, the inner wall of the body of the terminal connector includes a first circumferential end segment and a second circumferential end segment and a center segment, the center segment is disposed between the first circumferential end segment and the second circumferential end segment and is separated from the first circumferential end segment and the second circumferential end segment by a first opening and a second opening in the terminal connector, and a portion of one of the first circumferential end segment, the second circumferential end segment and the center segment is spaced from the radially inner wall to define a first recess, the first recess being configured to receive one of the start portion and the end portion of the coil.

[0095] Statement 48. A bobbin wound coil according to any one of Statements 41-47, wherein the axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange, the first recess being defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

[0096] Statement 49. The bobbin wound coil of any of statements 41-48, further comprising an anti-rotation 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.

[0097] Statement 50. The bobbin wound coil of any of statements 41-48 further comprising means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0098] Statement 51. A method for forming a bobbin-wound coil for an electromagnetic coupler, comprising: providing a bobbin, the bobbin including a cylindrical body arranged about a central axis; a first end flange, the first end flange being arranged at a first axial end of the cylindrical body and extending radially outward from the first axial end, 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, the second end flange being arranged at a second axial end of the cylindrical body and extending radially outward from the second axial end, 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 located on the outer side of the first end flange, the terminal connector including a body defining a central cavity; and a first column 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 an end portion of the coil through the first end flange and the terminal connector; and winding one of the starting portion and the end portion of the coil around the first column.

[0099] Statement 52. The method of forming a bobbin wound coil for an electromagnetic coupler of statement 51 wherein the terminal connector includes a locking tab extending from an outer surface of a body of the terminal connector and the first post is radially aligned with the locking tab.

[0100] Statement 53. A method for forming a wire drum winding coil for an electromagnetic coupler according to statement 52, wherein the cross-section of the locking tab is triangular and the locking tab includes a radially extending edge along the 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 an inclined edge extending between the radially extending edge and the axially extending edge.

[0101] Statement 54. A method of forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 51-53, wherein the terminal connector also 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 portion and the end portion of the coil around the second post.

[0102] Statement 55. A method for forming a bobbin wound coil for an electromagnetic coupler according to statement 54, wherein the terminal connector also includes a third column and a fourth column extending from the outer surface of the body of the terminal connector, and the method includes winding one of the beginning and end portions of the coil around the third column and winding the other of the beginning and end portions of the coil around the fourth column.

[0103] Statement 56. A method for forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 51-55, further comprising inserting a beginning portion of the coil through a first opening in a terminal connector and a first opening in a first end flange, and inserting an end portion of the coil through a second opening in the terminal connector and a second opening in the first end flange, the second opening in the terminal connector being located in front of the first opening in the terminal connector in a first circumferential direction, and the second opening in the first end flange being located behind the first opening in the first end flange in the first circumferential direction, the beginning portion of the coil comprising a first section extending from the first opening in the terminal connector to the first opening in the first end flange, and the end portion of the coil comprising 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 end portion of the coil intersecting with the first section of the beginning portion of the coil.

[0104] Statement 57. A method for 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 an axially spaced inner wall and an outer wall, a circumferentially spaced first side wall and a second side wall extending between the inner wall and the outer wall, and a radially inner side wall extending between the inner wall and the outer wall, the inner wall of the body of the terminal connector includes a first circumferential end segment and a second circumferential end segment and a center segment, the center segment is arranged between the first circumferential end segment and the second circumferential end segment and is separated from the first circumferential end segment and the second circumferential end segment by a first opening and a second opening in the terminal connector, and a portion of one of the first circumferential end segment, the second circumferential end segment and the center segment is spaced from the radially inner side wall to define a first recess, the method further comprising: inserting a starting portion of the coil through the first opening in the inner wall of the terminal connector; and inserting an end portion of the coil through the second opening in the inner wall of the terminal connector, wherein one of the starting portion and the end portion of the coil extends through the first recess.

[0105] Statement 58. A method for forming a bobbin wound coil for an electromagnetic coupler according to any one of Statements 51-57, wherein the axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange, the first recess being defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

[0106] Statement 59. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 51-58, wherein the bobbin further comprises an anti-rotation 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.

[0107] Statement 60. The method of forming a bobbin wound coil for an electromagnetic coupler according to any of statements 51-59, wherein the bobbin further comprises means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

[0108] Statement 61. A bobbin for a coil of an electromagnetic coupler, comprising: a cylindrical body, the cylindrical body being arranged around a central axis; a first end flange, the first end flange being arranged at a first axial end of the cylindrical body and extending radially outward from the first axial end, 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, the second end flange being arranged at a second axial end of the cylindrical body and extending radially outward from the second axial end, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body, wherein the axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange, defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

[0109] Statement 62. The bobbin of statement 61 wherein the first sidewall is disposed between the first recess and a second recess in an outer side of the first end flange.

[0110] Statement 63. A bobbin according to statement 61, wherein the first end flange defines a second recess in the outer side of the first end flange, the second recess being defined by a radial inner wall, a radial outer wall, and a third side wall and a fourth side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a second opening extending through the radial outer wall and communicating with the second recess.

[0111] Statement 64. A bobbin for a coil of an electromagnetic coupler, comprising: a cylindrical body, the cylindrical body being arranged around a central axis; a first end flange, the first end flange being arranged at a first axial end of the cylindrical body and extending radially outward from the first axial end, 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, the second end flange being arranged at a second axial end of the cylindrical body and extending radially outward from the second axial end, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and an anti-rotation member, the anti-rotation member extending from one of the cylindrical body, the first end flange and the second end flange and being configured to engage a field shell of the electromagnetic coupler.

[0112] Statement 65. The bobbin of statement 64, wherein the anti-rotation member includes a first flat portion formed on a radially inner surface of the cylindrical body and configured to engage a second flat portion in the field housing.

[0113] Statement 66. The bobbin of statement 64, wherein the anti-rotation member comprises a lug extending from one of the first end flange and the second end flange into a recess in the field housing.

[0114] Statement 67. A bobbin for a coil of an electromagnetic coupler, comprising: a cylindrical body, the cylindrical body being arranged around a central axis; a first end flange, the first end flange being arranged at a first axial end of the cylindrical body and extending radially outward from the first axial end, 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, the second end flange being arranged at a second axial end of the cylindrical body and extending radially outward from the second axial end, the second end flange defining an inner side facing the cylindrical body and an outer side facing away from the cylindrical body; and a device for preventing the bobbin from rotating relative to a field shell of the electromagnetic coupler.

[0115] Statement 68. The bobbin of statement 67, wherein the means for preventing rotation of the bobbin relative to the field housing comprises a first flat formed on a radially inner surface of the cylindrical body and configured to engage a second flat in the field housing.

[0116] Statement 69. The bobbin of statement 67, wherein the means for preventing rotation of the bobbin relative to the field housing comprises a lug extending from one of the first end flange and the second end flange into a recess in the field housing.

[0117] While the invention has been shown and described with reference to one or more specific embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.

Claims

1. A bobbin winding coil for an electromagnetic coupler, comprising: A bobbin, 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 from the first axial end, 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 from the second axial end, 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 located on the outer side of the first end flange; and, A coil, the coil having a starting portion and an end portion, the starting portion extending through a first opening in the terminal connector and a first opening in the first end flange, the end portion extending through a second opening in the terminal connector and a second opening in the first end flange, the second opening in the terminal connector being located in front of the first opening in the terminal connector in a first circumferential direction, and the second opening in the first end flange being located behind the first opening in the first end flange in the first circumferential direction, the starting portion including a first section extending from the first opening in the terminal connector to the first opening in the first end flange, and the end portion including 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 end portion of the coil intersecting with the first section of the starting portion of the coil.

2. The bobbin winding coil according to claim 1, wherein: The first section of the start portion of the coil extends through the second opening in the terminal connector, and the first section of the end portion of the coil extends through the first opening in the terminal connector.

3. The bobbin winding coil according to any one of claims 1 to 2, wherein: The first end flange includes a first circumferential segment and a second circumferential segment having different axial thicknesses, so 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 segment 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 segment of the first end flange, and the starting portion of the coil includes a second segment, which extends radially inward from the first segment of the starting portion of the coil along the inner side of the first end flange in the first circumferential segment of the first end flange.

4. The bobbin winding coil according to claim 3, wherein: The second section of the starting portion of the coil extends radially inwardly from the first opening in the first end flange of the bobbin to the cylindrical body of the bobbin along an inner side of the first end flange in the first circumferential section of the first end flange.

5. The bobbin winding coil according to any one of claims 1 to 4, wherein: The terminal connector includes a body, which defines a central cavity, and the body includes axially spaced inner and outer walls, circumferentially spaced first and second side walls extending between the inner and outer walls, and a radially inner wall extending between the inner and outer walls, the inner wall of the body of the terminal connector includes a first circumferential end segment and a second circumferential end segment and a center segment, the center segment is arranged between the first circumferential end segment and the second circumferential end segment and is separated from the first circumferential end segment and the second circumferential end segment by corresponding openings in the first opening and the second opening in the terminal connector, and a portion of one of the first circumferential end segment, the second circumferential end segment and the center segment is spaced from the radially inner wall to define a first recess, and the first recess is configured to receive one of the starting portion and the end portion of the coil.

6. The bobbin winding coil according to claim 5, wherein: The first circumferential end segment, the second circumferential end segment, and another portion of one of the center segment are spaced apart from the radial inner wall to define a second recess configured to receive the other of the start portion and the end portion of the coil.

7. The bobbin winding coil according to any one of claims 5 to 6, wherein: A first portion of the central section is spaced apart from the radially inner sidewall to define the first recess, and the first recess is configured to receive the end portion of the coil.

8. The bobbin winding coil according to claim 7, wherein: A second portion of the central section is spaced apart from the radially inner sidewall to define a second recess, and the second recess is configured to receive the beginning portion of the coil.

9. The bobbin winding coil according to any one of claims 5 to 6, wherein: A first portion of the central section is spaced apart from the radially inner sidewall to define the first recess, and the first recess is configured to receive the start portion of the coil.

10. The bobbin winding coil according to any one of claims 1 to 9, wherein: The terminal connector comprises: a body defining a central cavity; and, a post extending from an outer surface of the body of the terminal connector; and, wherein one of the start portion and the end portion of the coil is wound around the column.

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

12. The bobbin winding coil according to claim 11, wherein: The locking tab has a triangular cross-section and includes a radially extending edge along the 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 an inclined edge extending between the radially extending edge and the axially extending edge.

13. The bobbin winding coil according to any one of claims 10 to 12, wherein: The terminal connector further includes a second pole extending from the outer surface of the body of the terminal connector, and the other of the start portion and the end portion of the coil is wound around the second pole.

14. The bobbin winding coil according to claim 13, wherein: The terminal connector includes a third column and a fourth column 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 column, the second column, the third column and the fourth column, and the end portion of the coil is wound around the other two of the first column, the second column, the third column and the fourth column.

15. The bobbin winding coil according to any one of claims 1 to 14, wherein: The axial thickness of the first end flange varies to define a first recess in the outer side of the first end flange, the first recess being defined by a radial inner wall, a radial outer wall, and a first side wall and a second side wall extending radially between the radial inner wall and the radial outer wall, the radial outer wall including a first opening extending through the radial outer wall and communicating with the first recess.

16. The bobbin wound coil of any one of claims 1 to 15, further comprising an anti-rotation 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.

17. A bobbin wound coil according to any one of claims 1 to 15, further comprising means for preventing rotation of the bobbin relative to the field shell of the electromagnetic coupler.

Images