Bobbin for winding low-stress coil wire

Abstract

A bobbin (272c, 1072c, 1172c, 1372c) for winding a low stress coil wire is provided. The bobbin (272c, 1072c, 1172c, 1372c) includes a coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03) extending between a proximal end and a distal end of the bobbin (272c, 1072c, 1172c, 1372c), and a wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) at the proximal end. The wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) comprises one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-03) extending through the wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) to the coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03), and the one or more wire guide grooves (272c-09, 272c-12

Description

Technical Field

[0001] The embodiments described below relate to bobbins for coil wire, and more particularly to bobbins for low-stress coil wire winding. Background Art

[0002] A coil transducer typically includes a coil of wire arranged around a bobbin having a hollow interior. A magnet moves in and out of the hollow interior of the bobbin, generating an electric current. The magnitude of the current is proportional to the speed of the magnet and the strength of the magnetic field provided by the magnet. Conversely, the current supplied to the coil can induce a magnetic field. The magnetic field of the coil can interact with the magnetic field of the magnet, inducing opposing forces on the coil wire and the magnet. Therefore, a coil transducer can be used to convert an electrical signal into a mechanical force and / or convert a mechanical velocity into an electrical signal.

[0003] The coil wire winding machine can wind the coil wire around the bobbin. The coil wire winding machine can start the coil winding operation by inserting the coil wire into the coil wire feed groove. The coil wire feed groove can be designed to limit the circumferential movement of the coil wire while the coil wire winding machine winds the coil wire circumferentially around the bobbin. As can be understood, the coil winding operation can induce stress in the coil wire.

[0004] However, some industries may require significant precision and reliability from coil transducers, particularly the coil wire wound around a bobbin. For example, some applications may require the coil wire to have a resistance within certain specifications over a wide temperature range. Other applications may require the coil wire to not fail during significant mechanical stresses, such as vibration, shock, etc. The stress induced by the coil winding operation may affect the precision and reliability of the coil transducer. Therefore, there is a need for low-stress coil wire winding, and particularly bobbins for low-stress coil wire winding. Summary of the Invention

[0005] A bobbin for low-stress coil wire winding is provided. According to an embodiment, the bobbin includes a coil groove extending between a proximal end and a distal end of the bobbin, and a wire guide head located at the proximal end. The wire guide head includes one or more wire guide grooves extending through the wire guide head to the coil groove. One or more wire guide grooves are curvilinear.

[0006] A coil transducer having a bobbin for low-stress coil wire winding is provided. According to an embodiment, the coil transducer comprises a magnet assembly and a coil assembly, the coil assembly comprising a coil and a bobbin according to the foregoing, the bobbin being disposed within the coil.

[0007] A sensor assembly having a bobbin for low-stress coil wire winding is provided. According to an embodiment, the sensor assembly includes a catheter and an opposing body, and a coil transducer according to the foregoing mechanically coupled to the catheter and the opposing body.

[0008] A method for forming a bobbin for low-stress coil wire winding is provided. According to an embodiment, the method includes forming a coil groove extending between a proximal end and a distal end of the bobbin and forming a wire guide head at the proximal end, wherein forming the wire guide head includes forming one or more wire guide grooves extending through the wire guide head to the coil groove, wherein the one or more wire guide grooves are curvilinear.

[0009] A method for forming a coil transducer is provided. According to an embodiment, the method comprises providing a bobbin according to any of the preceding claims, placing a coil wire in one of the one or more wire guide grooves, and winding the coil wire around the bobbin and into the coil groove, wherein the coil wire is curved in one of the one or more wire guide grooves.

[0010] All aspects

[0011] According to one aspect, a bobbin for winding low-stress coil wire includes a coil groove extending between a proximal end and a distal end of the bobbin and a wire guide head at the proximal end, the wire guide head including one or more wire guide grooves extending through the wire guide head to the coil groove. The one or more wire guide grooves are curvilinear.

[0012] Preferably, the coil groove extending between the proximal and distal ends comprises a coil groove extending between a coil groove lip at the distal end of the bobbin and a coil groove shoulder at the proximal end of the bobbin.

[0013] Preferably, the radial distance of the coil groove lip at the distal end of the bobbin is substantially equal to the radial distance of the coil groove shoulder at the proximal end of the bobbin.

[0014] Preferably, the radial distance of the wire guide head is greater than the radial distance of the coil groove shoulder.

[0015] Preferably, the wire guiding head includes a wire guiding head chamfer extending from a radial distance of the wire guiding head to a radial distance of the coil groove shoulder.

[0016] Preferably, the one or more wire guide grooves extending through the wire guide head to the coil groove include at least one of the following: one or more wire guide grooves radially inclined from the radial distance of the wire guide head to the radial distance of the coil groove, and one or more wire guide grooves bent along the circumference from the proximal end of the bobbin to the coil groove.

[0017] Preferably, the one or more wire guiding grooves include a wire guiding bevel, wherein the radial distance of the wire guiding head includes the radial distance of the wire guiding bevel.

[0018] Preferably, the one or more wire guide grooves include at least one of a wire guide inner wall and a wire guide outer wall, the wire guide outer wall being configured to hold and bend the coil wire.

[0019] Preferably, the wire guiding head portion includes a first wire bending guide portion and a second wire bending guide portion, and the first wire bending guide portion and the second wire bending guide portion each include one of the one or more wire guiding grooves.

[0020] Preferably, the first wire bend guide and the second wire bend guide have a radial distance greater than a radial distance of a wire guide backing disposed between the first wire bend guide and the second wire bend guide.

[0021] According to one aspect, a coil transducer has a bobbin for winding low-stress coil wire, the coil transducer comprising a magnet assembly and a coil assembly, the coil assembly comprising a coil and the bobbin according to the foregoing, the bobbin being disposed within the coil.

[0022] According to one aspect, a sensor assembly has a spool for low-stress coil wire winding, the spool including a catheter and an opposing body and a coil transducer according to the foregoing, the coil transducer being mechanically coupled to the catheter and the opposing body.

[0023] Preferably, the opposing body comprises one of a catheter, a reference body and a balance pole.

[0024] According to one aspect, a method of forming a bobbin for low-stress coil wire winding includes forming a coil groove extending between a proximal end and a distal end of the bobbin and forming a wire guide head at the proximal end, wherein forming the wire guide head includes forming one or more wire guide grooves extending through the wire guide head to the coil groove, wherein the one or more wire guide grooves are curvilinear.

[0025] Preferably, the coil groove formed extending between the proximal and distal ends of the bobbin includes a coil groove formed extending between a coil groove lip located at the distal end of the bobbin and a coil groove shoulder located at the proximal end of the bobbin.

[0026] Preferably, the radial distance of the coil groove lip at the distal end of the bobbin is substantially equal to the radial distance of the coil groove shoulder at the proximal end of the bobbin.

[0027] Preferably, the radial distance of the wire guide head is greater than the radial distance of the coil groove shoulder.

[0028] Preferably, the wire guiding head includes a wire guiding head chamfer extending from a radial distance of the wire guiding head to a radial distance of the coil groove shoulder.

[0029] Preferably, forming one or more wire guide grooves extending through the wire guide head to the coil groove includes at least one of the following: forming one or more wire guide grooves radially inclined from a radial distance of the wire guide head to a radial distance of the coil groove; and forming one or more wire guide grooves that bend along the circumference from the proximal end of the bobbin to the coil groove.

[0030] Preferably, forming the one or more wire guiding grooves includes forming a wire guiding bevel, wherein the radial distance of the wire guiding head includes the radial distance of the wire guiding bevel.

[0031] Preferably, forming the one or more wire guide grooves includes forming at least one of a wire guide inner wall and a wire guide outer wall, the wire guide outer wall being configured to hold and bend the coil wire.

[0032] Preferably, forming the wire guiding head portion includes forming a first wire bending guide portion and a second wire bending guide portion, the first wire bending guide portion and the second wire bending guide portion each including one of the one or more wire guiding grooves.

[0033] Preferably, the first wire bend guide and the second wire bend guide have a radial distance greater than a radial distance of a wire guide backing disposed between the first wire bend guide and the second wire bend guide.

[0034] According to one aspect, a method of forming a coil transducer comprises providing a bobbin according to one of the preceding claims, placing a coil wire in one of the one or more wire guide grooves, and winding the coil wire around the bobbin and into the coil groove, wherein the coil wire is curved in the one or more wire guide grooves.

[0035] Preferably, the method further comprises disposing the coil wire in another one of the one or more wire guide grooves, wherein the coil wire is curved in the other one of the one or more wire guide grooves. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Like reference numerals represent like elements throughout the drawings.It should be understood that the drawings are not necessarily drawn to scale.

[0037] Figure 1 A vibrating meter 5 is shown including a bobbin for low stress coil wire winding.

[0038] Figure 2 and Figure 3 A sensor assembly portion 200 is shown, which includes a sensor assembly coupled to a reference Figure 1 The coil transducer 270 of the catheter 130, 130' is depicted.

[0039] Figure 4 A prior art spool 12c is shown.

[0040] Figures 5 to 9 Shown is a reference Figure 2 and Figure 3 A more detailed view of spool 272c is depicted.

[0041] Figure 10 An alternative bobbin 1072c for low stress coil wire winding is shown.

[0042] Figure 11 and Figure 12 An alternative bobbin 1172c for low stress coil wire winding is shown.

[0043] Figure 13 and Figure 14 An alternative bobbin 1372c for low stress coil wire winding is shown.

[0044] Figure 15 A method 1500 of forming a bobbin for low stress coil wire winding is shown.

[0045] Figure 16 A method 1600 of forming a coil transducer including a bobbin for low-stress coil wire winding is shown. DETAILED DESCRIPTION

[0046] Figures 1 to 16The following description depicts specific examples to teach those skilled in the art how to make and use the best mode of embodiment of a bobbin for winding low-stress coil wire. For the purpose of teaching the principles of the invention, some conventional aspects have been simplified or omitted. Those skilled in the art will understand variations from these examples that fall within the scope of this specification. Those skilled in the art will understand that the features described below can be combined in various ways to form a variety of variations of bobbins for winding low-stress coil wire. Therefore, the embodiments described below are not limited to the specific examples described below, but are only limited by the claims and their equivalents.

[0047] Figure 1 A vibrating meter 5 is shown including a bobbin for winding low-stress coil wire. Figure 1 As shown, the vibrating meter 5 includes a sensor assembly 10 and meter electronics 20. The sensor assembly 10 is responsive to the mass flow rate and density of the process material. The meter electronics 20 is connected to the sensor assembly 10 via leads 100 to provide density, mass flow rate, and temperature information, among other information, at a port 26.

[0048] The sensor assembly 10 includes a pair of manifolds 150 and 150', flanges 103 and 103' having flanged necks 110 and 110', a pair of parallel conduits 130 and 130', a driver 180, a resistance temperature detector (RTD) 190, and a pair of pickoff sensors 170l and 170r. The conduits 130 and 130' have two substantially straight inlet legs 131 and 131' and outlet legs 134 and 134' that converge toward each other at conduit mounting blocks 120 and 120'. The conduits 130 and 130' are curved at two symmetrical locations along their lengths and are substantially parallel throughout their lengths. Struts 140 and 140' define axes W and W' about which each conduit 130 and 130' oscillates. The legs 131 , 131 ′ and 134 , 134 ′ of the conduits 130 , 130 ′ are fixedly attached to the conduit mounting blocks 120 and 120 ′, and these blocks are in turn fixedly attached to the manifolds 150 and 150 ′. This provides a continuous closed material path through the sensor assembly 10 .

[0049] When flanges 103 and 103' having holes 102 and 102' are connected via inlet end 104 and outlet end 104' to a process line (not shown) carrying the process material being measured, the material enters the meter's inlet end 104 through open orifice 101 in flange 103 and is directed through manifold 150 to conduit mounting block 120 having surface 121. Within manifold 150, the material is separated and directed through conduits 130, 130'. Upon exiting conduits 130, 130', the process material recombines into a single stream within block 120' having surface 121' and manifold 150' and is then directed to outlet end 104', which is connected to the process line (not shown) via flange 103' having hole 102'.

[0050] The conduits 130, 130' are selected and appropriately mounted to the conduit mounting blocks 120, 120' so as to have substantially the same mass distribution, moment of inertia, and Young's modulus about the bending axes W--W and W'--W', respectively. These bending axes pass through the struts 140, 140'. Since the Young's modulus of the conduit varies with temperature, and this variation affects the calculation of flow and density, an RTD 190 is mounted to the conduit 130' to continuously measure the temperature of the conduit 130'. The temperature of the conduit 130' and therefore the voltage appearing on the RTD 190 for a given current passing through the RTD 190 is controlled by the temperature of the material passing through the conduit 130'. The temperature-dependent voltage appearing on the RTD 190 is used by the meter electronics 20 in a known manner to compensate for changes in the elastic modulus of the conduits 130, 130' caused by any changes in the conduit temperature. The RTD 190 is connected to the meter electronics 20 via leads 195.

[0051] Both conduits 130, 130' are driven by a driver 180 in opposite directions about their respective bending axes W and W', respectively, and in what is known as the first out-of-phase bending mode of the vibrating meter. Although two conduits 130, 130' are shown, any suitable arrangement may be employed. For example, a single conduit may be employed, with the driver 180 coupled to the conduit 130 and an opposing body. The opposing body may or may not oscillate in a counter-rotating manner relative to the conduit 130. The opposing body may include a reference body, such as a housing, a balance bar, or the like. In these and other examples, the driver 180 may include any of a number of well-known arrangements, such as a magnet mounted to the conduit 130' and an opposing coil mounted to the conduit 130, with alternating current passing through the opposing coil to vibrate both conduits 130, 130'. A suitable drive signal 185 is applied to the driver 180 via leads via the meter electronics 20. Thus, the vibrating meter 5, or more specifically, the sensor assembly 10, may be considered a symmetrical oscillating device, such as the symmetrical oscillating device 1 described above.

[0052] Meter electronics 20 receives the RTD temperature signal on lead 195 and sensor signal 165 present on lead 100, carrying left and right sensor signals 165l, 165r, respectively. Meter electronics 20 generates drive signal 185 that appears on leads to driver 180 and causes conduits 130, 130' to vibrate. Meter electronics 20 processes left and right sensor signals 165l, 165r, and the RTD signal carried on lead 195 to calculate the mass flow rate and density of the material passing through sensor assembly 10. This information, along with other information, is applied as a signal by meter electronics 20 to port 26.

[0053] As discussed above, the sensor assembly 10 includes a driver 180 and a pair of pickoff sensors 1701 and 170r. A portion of the driver 180 and the pickoff sensors 1701 and 170r may be a coil transducer that includes a bobbin for winding low-stress coil wire, as explained in more detail below.

[0054] Figure 2 and Figure 3 A sensor assembly portion 200 is shown, which includes the sensor assembly portion 200 shown in FIG. Figure 1 The described catheters 130, 130' are coupled to a coil transducer 270. The coil transducer 270 may be the pickup sensors 170l, 170r described above, however, the coil transducer 270 may be any suitable transducer including a bobbin for winding low-stress coil wire. For example, the coil transducer 270 may be the one described above with reference to Figure 1 Drive 180 is described.

[0055] Coil transducer 270 is mechanically coupled to catheters 130, 130'. Coil transducer 270 is mechanically coupled to catheters 130, 130' via brackets 220, 220'. More specifically, coil assembly 270c is mechanically coupled to first bracket 220, which is mechanically coupled to first catheter 130, and magnet assembly 270m is mechanically coupled to second bracket 220', which is mechanically coupled to second catheter 130'. Coil assembly 270c includes a bobbin 272c, an insert 274c, and a coil 276c disposed around bobbin 272c. Magnet assembly 270m includes a magnet 272m and a magnet holder 274m.

[0056] The brackets 220, 220' may be mechanically coupled to the conduits 130, 130' by brazing, welding, single-piece forging, and / or any other suitable means. Figure 2 As shown, the brackets 220, 220' are attached to the catheters 130, 130' by brazing. The coil transducer 270 is shown as being mechanically coupled to the brackets 220, 220' using screws as fasteners. However, alternative pick-off sensors may be attached to alternative brackets by any suitable means, such as brazing, welding, fastening, etc.

[0057] The coil transducer 270 may be a displacement sensor that includes two relatively positioned parts, which enables the coil transducer 270 to determine a relative displacement value between the two parts. As used herein, the term "displacement value" includes any value related to displacement, such as distance, velocity, acceleration, etc. Figure 2 As shown, the two parts of coil transducer 270 are coil assembly 270c and magnet assembly 270m.

[0058] Coil assembly 270c and magnet assembly 270m are shown as being symmetrically arranged between conduit 130,130 ', but have some overlap owing to complementary and non-interference type engagement.More specifically, coil assembly 270c has a cylindrical engagement portion, and this cylindrical engagement portion has the diameter less than the cylindrical engagement portion of magnet assembly 270m.Therefore, coil assembly 270c extends in magnet assembly 270m, and magnet assembly 270m surrounds coil assembly 270c simultaneously.

[0059] Coil assembly 270c is shown as including a bobbin 272c and an insert 274c that are mechanically coupled to each other. More specifically, bobbin 272c is attached to insert 274c. Figure 2 As shown, the bobbin 272c is overmolded onto the insert 274c. That is, the bobbin 272c may comprise a non-conductive substance, such as a polymer, ceramic, etc., which is overmolded onto the insert 274c. Figure 2270c, but the coil assembly 270c includes a coil wound around a bobbin 272c. The coil can carry current due to the magnetic field of the magnet assembly 270m.

[0060] The magnet assembly 270m is shown as including a magnet 272m and a magnet holder 274m. The magnet 272m and the magnet holder 274m are mechanically coupled to each other. More specifically, the magnet 272m is attached to the magnet holder 274m. The magnet 272m and the magnet holder 274m can be mechanically attached to each other using any suitable means, such as adhesives, press fits, fastening features, etc. The magnet 272m can provide a magnetic field that is shaped and converged by the magnet holder 274m. Therefore, the magnet holder 274m can include a paramagnetic material, but any suitable material that can shape and / or converge the magnetic field provided by the magnet 272m can also be used. Although the coil assembly 270c and the magnet assembly 270m are shown as including two different parts, other coil assemblies and magnet assemblies can include more or fewer parts respectively. For example, alternative coil assemblies can include a single integral material piece that is forged, machined, etc. Alternatively, other coil assemblies can include three or more parts.

[0061] Coil assembly 270c and magnet assembly 270m move together with conduit 130, 130' respectively. Therefore, coil assembly 270c and magnet assembly 270m move back and forth with each other. When conduit 130, 130' oscillates in the opposite direction, coil assembly 270c and magnet assembly 270m will also oscillate in the opposite direction. Therefore, the opposite oscillation of coil assembly 270c and magnet assembly 270m can cause the magnetic field of magnet assembly 270m to change in the coil of coil assembly 270c. Therefore, the coil of coil assembly 270c can provide an electric current proportional to the relative speed of coil assembly 270c and magnet assembly 270m. The electric current can be received by meter electronics, such as the above-mentioned meter electronics 20, to determine the measured value.

[0062] The shape and density of the insert 274c can be selected during design, prototyping, manufacturing, etc., however, any suitable method can be used to select the shape and density of the insert 274c. The insert 274c is shown as having a cylindrical shape with an internally threaded portion that engages with the bolt. The bolt provides a compressive force to the insert 274c and the first bracket 220. Therefore, the insert 274c and the first bracket 220 are compressed together. Figure 2 As shown, insert 274c includes a retaining groove that engages with the retaining tongue of spool 272c. Figure 2 As shown, the bobbin 272 c is also compressed toward the first bracket 220 , and the bobbin 272 c does not abut the first bracket 220 .

[0063] The above-mentioned bobbin 272c is different from the prior art bobbin. Figure 4 Description of Prior Art Spools

[00106] The differences between spool 272c and prior art spools are initially described.

[0064] Prior art spools

[0065] Figure 4 A prior art coil bobbin 12c is shown. Figure 4 As shown, the bobbin 12c has a hollow cylindrical shape with a lip on each end. The lips and the outer surface of the bobbin 12c form a coil groove 12cg. In addition, one of the lips includes a wire groove 12cw. During assembly, when the wire winding tool winds the coil wire around the coil groove 12cg, the wire groove 12cw is used to hold the coil wire. Figure 4 As can be seen in the figure, the outer surface of the wire groove 12cw is parallel and coplanar with the coil groove 12cg. The wire groove 12cw is also completely linear. That is to say, the inner wall, outer wall and bottom of the wire groove 12cw do not have a radius of curvature. Therefore, the completely linear wire groove 12cw ends at the sharp corner of the lip of the bobbin 12c. This causes the coil wire to be pressed against the sharp corner where the wire groove 12cw meets the coil groove 12cg. Therefore, the coil wire may experience significant local stress or stress concentration, and therefore may have strain that affects the mechanical and electrical properties of the coil wire. Additionally or alternatively, the coil wire may have stress fractures, microfractures, fatigue, etc. Local stress may also cause the coil wire to malfunction during winding, such as breaking the wire.

[0066] Spool with curved wire guiding grooves

[0067] With reference Figure 4 In contrast to the completely linear wire groove 12cw of the bobbin 12c described above, a bobbin including a curvilinear wire guide groove is described below. For example, the wire guide portion can be radially inclined from the radial distance of the wire guide head of the bobbin to the radial distance of the coil groove. Additionally or alternatively, the wire guide groove can be curved along the periphery (along the periphery of the bobbin) from the end of the wire guide head to the coil groove. Because the wire guide groove is curvilinear, the local stress in the coil wire can be significantly less than Figure 4 The local stress in the coil wire wound around the bobbin 12c is shown in FIG.

[0068] Figures 5 to 9 Shown is a reference Figure 2 and Figure 3 A more detailed view of the spool 272c is depicted. Figures 5 to 9In the figure, for the sake of clarity, the insert 274c and the coil 276c are not shown. As shown, the bobbin 272c has a hollow cylindrical shape with a center line CL of the coil bobbin. 272c As described in more detail below, the bobbin 272c and / or the wire winding tool can be arranged around the coil bobbin centerline CL 272c Rotate to form the above-mentioned coil 276c.

[0069] Spool 272c Figure 5 2. The coil groove lip 272c-01 and the coil groove shoulder 272c-02 are shown as including the coil groove lip 272c-01 and the coil groove shoulder 272c-02. Between the coil groove lip 272c-01 and the coil groove shoulder 272c-02 is the coil groove 272c-03. The coil groove shoulder 272c-02 is shown as a feature of the bobbin base 272c-04. As can be understood, the coil groove lip 272c-01, the coil groove shoulder 272c-02 and the coil groove 272c-03 are about the coil bobbin centerline CL. 272c That is, the coil groove lip 272c-01, the coil groove shoulder 272c-02 and the coil groove 272c-03 include a portion around the coil bobbin centerline CL. 272c A surface extending along the periphery at orthogonal radial symmetric distances. When the bobbin is cylindrical, such as Figure 5 When referring to the spool 272c shown in FIG, the periphery may alternatively be referred to as the circumference.

[0070] The bobbin base 272c-04 also includes a wire guide head 272c-05 extending radially from the bobbin base 272c-04. Figure 5 Shown in and Figures 6 to 8 The wire guide head 272c-05 shown in more detail in FIG can be used by a wire winding machine to wind the coil wire around the bobbin 272c and into the coil groove 272c-03. Figure 5 , it will be appreciated that the wire guide head 272c-05 extends radially from the peripheral surface of the bobbin base 272c-04. The bobbin base 272c-04 is shown as having a cylindrical shape having a base chamfered surface 272c-06. As can be seen, the base chamfered surface 272c-06 extends from the outer portion of the bobbin base 272c-04 to the coil groove shoulder 272c-02 at a gradually decreasing radial distance. Thus, the base chamfered surface 272c-06 forms an inclined surface or ramp surface in the bobbin base 272c-04 that extends toward the coil groove 272c-03.

[0071] like Figures 5 to 8As shown, the wire guide head 272c-05 includes a first coil winding guide 272c-07 and a second coil winding guide 272c-08. The first coil winding guide 272c-07 and the second coil winding guide 272c-08 can be an inlet wire winding guide and an outlet wire winding guide, respectively, but any suitable arrangement and / or terminology can be used. The first coil winding guide 272c-07 and the second coil winding guide 272c-08 can capture the coil wire in the circumferential direction and restrict the coil wire during winding around the bobbin 272c.

[0072] exist Figures 6 to 8 In a more detailed view of the first coil winding guide 272c-07 and the second coil winding guide 272c-08 are shown as including a first wire guide groove 272c-09 and a first wire bend guide 272c-10, as well as a second wire guide groove 272c-12 and a second wire bend guide 272c-13, respectively. A wire guide backing 272c-11 is provided between the first wire bend guide 272c-10 and the second wire bend guide 272c-13. The first wire guide groove 272c-09 is located between the first wire bend guide 272c-10 and the wire guide backing 272c-11 and is partially defined by the first wire bend guide 272c-10 and the wire guide backing 272c-11. Similarly, the second wire guide groove 272c-12 is located between and partially defined by the second wire bend guide 272c-13 and the wire guide backing 272c-11.

[0073] like Figure 7 and Figure 8 As shown, the first wire guide groove 272c-09 includes a first wire guide inner wall 272c-14, a first wire guide bevel 272c-16, and a first wire guide outer wall 272c-15. Similarly, the second wire guide groove 272c-12 includes a second wire guide inner wall 272c-17, a second wire guide bevel 272c-19, and a second wire guide outer wall 272c-18. The terms "inner" and "outer" when used in describing the features of the wire guide head 272c-05 can refer to the inner surface area and outer surface area of ​​the wire guide head 272c-05, respectively. As can be appreciated, the first and second wire guide inner walls 272c-14 and 272c-17, the first and second wire guide slopes 272c-16 and 272c-19, and the first and second wire guide outer walls 272c-15 and 272c-18 are composed of curved surfaces.

[0074] For example, the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 include corresponding symmetrical arc portions that are radially inclined from the outer portion of the wire guide head 272c-05 and are circumferentially curved to the coil groove shoulder 272c-02. The peripheral curved portions of the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 (e.g., curved portions in a direction along the peripheral surface of the bobbin base 272c-04) are formed by Figure 7 Shown from a side view.

[0075] Therefore, near the outer portion of the wire guide head 272c-05, the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 extend from a direction substantially perpendicular to the plane formed by the outer portion of the wire guide head 272c-05 to a direction substantially parallel to the coil groove shoulder 272c-02. The arcuate shape of the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 does not have a constant radius of curvature, but rather has a radius of curvature that gradually increases as the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 extend from the outer portion of the wire guide head 272c-05.

[0076] As can also be seen, the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 have significant lengths. For example, the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 are several times greater than the width of the first wire guide slope 272c-16 and the second wire guide slope 272c-19. Thus, the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 are many times greater than the width of any wire guided by the first wire guide groove 272c-09 and the second wire guide groove 272c-12.

[0077] As from Figure 5 and Figure 6 As can be appreciated, the wire guide backing 272c-11 does not extend as far from the bobbin base 272c-04 as the first wire bend guide 272c-10 and the second wire bend guide 272c-13. More specifically, the wire guide backing 272c-11 has a chamfered portion that is at the same radial distance as the base chamfered surface 272c-06 near the coil groove shoulder 272c-02. Furthermore, near the coil groove shoulder 272c-02, the first wire bend guide 272c-10 and the second wire bend guide 272c-13 extend further from the bobbin base 272c-04 than the wire guide backing 272c-11.

[0078] Thus, during winding, when the longitudinally aligned coil wire is wound around the coil bobbin centerline CL 272c When displaced circumferentially, the first wire bending guide 272c-10 and the second wire bending guide 272c-13 extend longitudinally (eg, substantially parallel to the coil bobbin centerline CL). 272c ) can be captured by the first wire bending guide 272c-10 or the second wire bending guide 272c-13. After capturing the coil wire, the coil winding machine can press and / or pull the coil wire into the first wire guide groove 272c-09 or the second wire guide groove 272c-12.

[0079] For example, Figure 8 A portion of the coil 276c is shown as a double-arrow end line. The arrows at the ends of the double-arrow end line depict exemplary tension applied to the illustrated portion of the coil 276c. The double-arrow end line illustrates exemplary positions and arrangements of the coil wire during winding. Figure 8 As shown, the coil 276c is pressed against the first wire guide outer wall 272c-15 and the second wire guide outer wall 272c-18 due to the tension depicted by the arrows. In addition, one of the double-arrow end lines is arranged close to the coil groove 272c-03, and the other of the double-arrow end lines is arranged close to the base chamfered surface 272c-06, which may be caused by the coil 276c entering and exiting the coil groove 272c-03.

[0080] in addition, Figure 9 A side view of a bobbin 272c for winding low stress coil wire is shown. Figure 9 , the bobbin 272c is shown as being around the coil bobbin centerline CL 272c The bobbin 272c is also shown as including the aforementioned bobbin base 272c-04, coil groove shoulder 272c-02, coil groove 272c-03, and coil groove lip 272c-01. The bobbin base 272c-04 includes a base chamfered surface 272c-06 that extends from an outer portion of the bobbin base 272c-04 to the coil groove shoulder 272c-02. Also shown is a wire guide head 272c-05, which is shown as including a second wire bend guide 272c-13 and a wire guide backing 272c-11 due to the side perspective view. A second wire guide ramp 272c-19 is shown in phantom.

[0081] Also shown is a diagram showing the distance of a feature on the surface of the bobbin 272c from the coil bobbin centerline CL. 272c For example, the outer portion or closest portion of the spool base 272c-04 is shown as having a spool base radial distance rcb The coil groove lip 272c-01 is shown with a coil groove lip radial distance r cl , which is shown as the distance from the peripheral surface of the coil groove lip 272c-01 to the coil bobbin centerline CL 272c Similarly, the coil groove shoulder 272c-02 has a coil groove shoulder radial distance r cs , which is essentially equal to the radial distance r from the coil groove lip cl The coil groove 272c-03 is shown as having a coil groove radial distance r cg , which is less than the radial distance r of the coil groove shoulder cs Radial distance r from the coil groove lip cl In addition, the wire guide head 272c-05 is shown as having various radial distances. For example, the second wire bend guide 272c-13 is shown as having a second bend guide radial distance r wbs , and the wire guide backing 272c-11 is shown with a wire guide backing radial distance r wcs The second wire bending guide 272c-13 is shown as having a second bending guide chamfer radial distance r ihc .

[0082] although Figure 9 No reference numerals are explicitly used in the drawings, but in consideration of Figures 5 to 9 When the wire guide backing 272c-11 is shown, it can be understood that the radial distance of the wire guide backing 272c-11 from the coil groove shoulder 272c-02 is approximately equal to the radial distance r of the coil groove shoulder. cs . Similarly, although Figure 9 There is no explicit numerical marking in FIG, but the radial distance between the outer portion of the spool base and the radial distance r of the wire guide backing is wcs The radial distance of the end of the second wire guide slope 272c-19 close to the outer portion of the bobbin base is substantially the same. The end of the second wire guide slope 272c-19 close to the coil groove shoulder 272c-02 has a radial distance r from the coil groove shoulder. cs Basically equal radial distances.

[0083] As from Figure 9 as well as Figures 5 to 8 It can also be understood that the radial distance of the first curved guide portion (not shown) is equal to the radial distance r of the second curved guide portion. wbs . As from Figure 9 It can be understood that the radial distance r of the wire guide backing wcsThe radial distance of the second wire bending guide portion 272c-13 is greater than the radial distance of the chamfered portion of the second wire bending guide portion 272c-13 near the midpoint of the chamfered portion. At the end of the chamfered portion of the second wire bending guide portion 272c-13, the radial distance of the second wire bending guide portion 272c-13 is greater than the distance from the wire guide backing 272c-11 to the coil bobbin centerline CL 272c The radial distance of the common point on the .

[0084] Therefore, the second wire bending guide 272c-13 is close to and around the coil bobbin center line CL. 272c While moving along the periphery, it moves along a direction substantially parallel to the coil bobbin centerline CL. 272c The coil wire (not shown) extending in the direction of the coil bobbin can be restricted by the wire guide backing 272c-11 from moving further toward the wire guide backing 272c-11. In addition, if the coil wire is close to the wire guide backing 272c-11 and is guided around the coil bobbin centerline CL 272c While moving along the periphery, it moves along a direction substantially parallel to the coil bobbin centerline CL. 272c If the wire is extended in the direction of the second wire bending guide portion 272c-13, further movement toward the second wire bending guide portion 272c-13 may be restricted by the second wire bending guide portion 272c-13.

[0085] Additionally, the second wire guide ramp 272c-19 is shown radially sloped from the outer portion of the bobbin base 272c-04 to the coil groove 272c-03. More specifically, the second wire guide ramp 272c-19 is a radial distance r from the wire guide backing. wcs Radial distance r from radial inclination to coil groove cg As can be seen, the radially inclined surface of the second wire guide slope 272c-19 is curved, wherein the ends of the second wire guide slope 272c-19 are substantially parallel to the outer portion of the bobbin base 272c-04 and the coil groove 272c-03, respectively. Figure 8 and Figure 9 Due to the second wire guide slope 272c-19, the coil wire may not be subjected to stress, such as bending stress, in the second wire guide groove 272c-12.

[0086] The aforementioned bobbin 272c includes a wire guide head 272c-05 including a first wire bend guide 272c-10 and a second wire bend guide 272c-13 having a chamfered portion and a relatively large surface area. Other coil bobbins having alternative curved wire guides may be employed, examples of which are described below.

[0087] Alternative bobbins for low-stress coil wire winding

[0088] Figure 10 An alternative bobbin 1072c for low stress coil wire winding is shown. Figure 10 As shown, the bobbin 1072c has a hollow cylindrical shape with respect to the coil bobbin centerline CL. 1072c The bobbin 1072c or wire winding tool can be symmetrical around the coil bobbin centerline CL 1072c Rotated to form a coil similar to coil 276c described above.

[0089] Spool 1072c Figure 10 1 and 2. The coil groove lip 1072c-01 and the coil groove shoulder 1072c-02 are shown as including a coil groove lip 1072c-01 and a coil groove shoulder 1072c-02. Between the coil groove lip 1072c-01 and the coil groove shoulder 1072c-02 is a coil groove 1072c-03. The coil groove shoulder 1072c-02 is shown as a feature of the spool base 1072c-04. As can be understood, similar to the above-mentioned spool 272c, the coil groove lip 1072c-01, the coil groove shoulder 1072c-02 and the coil groove 1072c-03 are about the coil spool centerline CL. 1072c Basically symmetrical.

[0090] The bobbin base 1072c-04 also includes a wire guide head 1072c-05 extending radially from the bobbin base 1072c-04. The wire guide head 1072c-05 can be used to wind the coil wire around the bobbin 1072c in the coil groove 1072c-03. Figure 10 As can be seen in the figure, the wire guide head 1072c-05 extends radially from the peripheral surface of the spool base 1072c-04. The spool base 1072c-04 is shown as having a cylindrical shape, which has a base chamfered surface 1072c-06. As can be seen, the base chamfered surface 1072c-06 extends from the outer portion of the spool base 1072c-04 to the coil groove shoulder 1072c-02 at a gradually decreasing radial distance. Thus, the base chamfered surface 1072c-06 forms an inclined surface or ramp surface extending toward the coil groove 1072c-03.

[0091] like Figure 10 As shown, the wire guide head 1072c-05 includes a first wire winding guide 1072c-07 and a second wire winding guide 1072c-08. The first wire winding guide 1072c-07 and the second wire winding guide 1072c-08 can be an entry wire winding guide and an exit wire winding guide, respectively, but any suitable arrangement and / or terminology can be used. The first wire winding guide 1072c-07 and the second wire winding guide 1072c-08 can capture the coil wire in the circumferential direction and restrain the coil wire during winding around the bobbin 1072c.

[0092] exist Figure 10 , the first wire winding guide 1072c-07 and the second wire winding guide 1072c-08 are shown as including a first wire guide groove 1072c-09 and a first wire bend guide 1072c-10, as well as a second wire guide groove 1072c-12 and a second wire bend guide 1072c-13, respectively. A wire guide backing 1072c-11 is provided between the first wire bend guide 1072c-10 and the second wire bend guide 1072c-13. The first wire guide groove 1072c-09 is located between the first wire bend guide 1072c-10 and the wire guide backing 1072c-11 and is at least partially defined by the first wire bend guide 1072c-10 and the wire guide backing 1072c-11. Similarly, the second wire guide groove 1072c-12 is located between and at least partially defined by the second wire bend guide 1072c-13 and the wire guide backing 1072c-11.

[0093] like Figure 10 As shown, the first wire guide groove 1072c-09 includes a first wire guide inner wall 1072c-14, a first wire guide bevel 1072c-16, and a first wire guide outer wall 1072c-15. Similarly, the second wire guide groove 1072c-12 includes a second wire guide inner wall 1072c-17, a second wire guide bevel 1072c-19, and a second wire guide outer wall 1072c-18. As can be understood, the first wire guide inner wall 1072c-14 and the second wire guide inner wall 1072c-17, the first wire guide bevel 1072c-16 and the second wire guide bevel 1072c-19, and the first wire guide outer wall 1072c-15 and the second wire guide outer wall 1072c-18 are formed of curved surfaces.

[0094] For example, the first wire guide outer wall 1072c-15 and the second wire guide outer wall 1072c-18 include symmetrical arcs that curve from the outer portion of the wire guide head 1072c-05 to the coil groove shoulder 1072c-02. Near the outer portion of the wire guide head 1072c-05, the first wire guide outer wall 1072c-15 and the second wire guide outer wall 1072c-18 curve from a direction substantially perpendicular to the plane formed by the outer portion of the wire guide head 1070 to a direction substantially parallel to the coil groove shoulder 1072c-02. The arcuate shapes of the first and second wire guide outer walls 1072c-15 and 1072c-18 do not have a constant radius of curvature, but rather have a radius of curvature that gradually increases as the first and second wire guide outer walls 1072c-15 and 1072c-18 extend from the outer portion of the wire guide head 1072c-05.

[0095] As can also be seen, the first wire guide outer wall 1072c-15 and the second wire guide outer wall 1072c-18 have a significant length, which is in a direction substantially perpendicular to the radius of the spool base 1072c-04. For example, the length of the first wire guide outer wall 1072c-15 and the second wire guide outer wall 1072c-18 is several times greater than the width of the first wire guide slope 1072c-16 and the second wire guide slope 1072c-19. Therefore, the length of the first wire guide outer wall 1072c-15 and the second wire guide outer wall 1072c-18 is several times greater than the width of any wire guided by the first wire guide groove 1072c-09 and the second wire guide groove 1072c-12.

[0096] like Figure 10 As can be appreciated, the wire guide backing 1072c-11 does not extend as far from the spool base 1072c-04 as the first wire bend guide 1072c-10 and the second wire bend guide 1072c-13. More specifically, the wire guide backing 1072c-11 has a chamfered portion that is at the same radial distance as the base chamfered surface 1072c-06 near the coil groove shoulder 272c-02. Furthermore, near the coil groove shoulder 1072c-02, the first wire bend guide 1072c-10 and the second wire bend guide 1072c-13 extend further from the spool base 1072c-04 than the wire guide backing 1072c-11.

[0097] Therefore, during winding, as the coil wire winds around the coil bobbin centerline CL 1072c When circumferentially displaced, the longitudinal direction (eg, substantially parallel to the coil bobbin centerline CL) between the first wire bending guide 1072c-10 and the second wire bending guide 1072c-13 is substantially parallel to the coil bobbin centerline CL.1072c ) The coil wire extending from the first wire bending guide 1072c-10 or the second wire bending guide 1072c-13 may be captured. After capturing the coil wire, the coil winding machine may press the coil wire into the first wire guide groove 1072c-09 or the second wire guide groove 1072c-12.

[0098] The bobbin 272c, 1072c is described above as including a wire guide head 272c-05, 1072c-05 having two wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12. Furthermore, the wire guide head 272c-05, 1072c-05 is configured to capture the coil wire during winding. The following describes embodiments including a wire guide head having a single wire guide groove and a wire guide head that does not capture the coil wire.

[0099] Alternative spool with single wire winding groove

[0100] Figure 11 and Figure 12 An alternative bobbin 1172c for low stress coil wire winding is shown. The alternative bobbin 1172c has a single wire guide groove, as discussed in more detail below. Figure 11 and Figure 12 As shown, the bobbin 1172c has a hollow cylindrical shape with respect to the coil bobbin centerline CL. 1172c The bobbin 1172c or wire winding tool can be symmetrical around the coil bobbin centerline CL 1172c Rotated to form a coil similar to coil 276c described above.

[0101] Spool 1172c Figure 11 and Figure 12 1 and 2. The coil groove lip 1172c-01 and the coil groove shoulder 1172c-02 are shown as including a coil groove lip 1172c-01 and a coil groove shoulder 1172c-02. Between the coil groove lip 1172c-01 and the coil groove shoulder 1172c-02 is a coil groove 1172c-03. The coil groove shoulder 1172c-02 is shown as a feature of the spool base 1172c-04. As can be understood, similar to the above-mentioned spools 272c and 1072c, the coil groove lip 1172c-01, the coil groove shoulder 1172c-02 and the coil groove 1172c-03 are about the coil spool centerline CL. 1172c Basically symmetrical.

[0102] The bobbin base 1172c-04 also includes a wire guide head 1172c-05 extending radially from the bobbin base 1172c-04. The wire guide head 1172c-05 can be used to wind the coil wire around the bobbin 1172c in the coil groove 1172c-03. Figure 11 and Figure 12 As can be appreciated, the wire guide head 1172c-05 extends radially from the peripheral surface of the bobbin base 1172c-04. The bobbin base 1172c-04 is shown as having a cylindrical shape with a base chamfered surface 1172c-06. As can be seen, the base chamfered surface 1172c-06 extends from the outer portion of the bobbin base 1172c-04 to the coil groove shoulder 1172c-02 at a gradually decreasing radial distance and with a curvature. Thus, the base chamfered surface 1172c-06 forms an inclined surface or ramped surface extending toward the coil groove 1172c-03.

[0103] like Figure 11 and Figure 12 As shown, the wire guide head 1172c-05 includes a first wire winding guide 1172c-07 and a second wire winding guide 1172c-08. The first wire winding guide 1172c-07 and the second wire winding guide 1172c-08 can be an inlet wire winding guide and an outlet wire winding guide, respectively, but any suitable arrangement and / or terminology can be used. The first wire winding guide 1172c-07 and the second wire winding guide 1172c-08 can capture the coil wire in the circumferential direction and restrain the coil wire during winding around the bobbin 1172c.

[0104] exist Figure 11 and Figure 12 In the embodiment of the present invention, the first wire winding guide 1172c-07 and the second wire winding guide 1172c-08 are shown as including a wire guide groove 1172c-09 and a first wire bend guide 1172c-10 and a second wire bend guide 1170c-13, respectively. Compared to the aforementioned spools 272c and 1072c, no wire guide backing is provided between the first wire bend guide 1172c-10 and the second wire bend guide 1172c-13. Therefore, a single wire guide groove 1172c-09 is employed. The wire guide groove 1172c-09 is located between the first wire bend guide 1172c-10 and the second wire bend guide 1172c-13 and is at least partially defined by the first and second wire bend guides 1172c-10 and 1172c-13.

[0105] like Figure 11 and Figure 12As shown, the wire guide groove 1172c-09 includes a first wire guide outer wall 1172c-15, a wire guide bevel 1172c-16 and a second wire guide outer wall 1172c-18. As can be understood, the wire guide bevel 1172c-16 and the first wire guide outer wall 1172c-15 and the second wire guide outer wall 1172c-18 are composed of curved surfaces.

[0106] For example, the first wire guide outer wall 1172c-15 and the second wire guide outer wall 1172c-18 include symmetrical arcs that curve from the outer portion of the wire guide head 1172c-05 to the coil groove shoulder 1172c-02. Near the outer portion of the wire guide head 1172c-05, the first wire guide outer wall 1172c-15 and the second wire guide outer wall 1172c-18 curve from a direction substantially perpendicular to the plane formed by the outer portion of the wire guide head 1170c-05 to a direction substantially parallel to the coil groove shoulder 1172c-02. The arcuate shapes of first and second wire guide outer walls 1172c-15 and 1172c-18 do not have a constant radius of curvature, but rather have a radius of curvature that gradually increases as they extend from the outer portion of wire guide head 1172c-05.

[0107] As can also be seen, first wire guide outer wall 1172c-15 and second wire guide outer wall 1172c-18 have a significant length, which is perpendicular to the radius of spool base 1172c-04. However, compared to spools 272c and 1072c described above, the lengths of first wire guide outer wall 1172c-15 and second wire guide outer wall 1172c-18 are no greater than several times the width of wire guide ramps 1172c-16 and 1172c-19. Regardless, the lengths of first wire guide outer wall 1172c-15 and second wire guide outer wall 1172c-18 are greater than several times the width of any coil wire guided by wire guide grooves 1172c-09 and 1172c-12.

[0108] During winding, as the coil wire winds around the coil bobbin centerline CL 1172c When displaced circumferentially, the longitudinal direction (eg, substantially parallel to the coil bobbin centerline CL) between the first wire bending guide 1172c-10 and the second wire bending guide 1172c-13 is substantially parallel to the coil bobbin centerline CL. 1172c ) The coil wire extending from the first wire bending guide 1172c-10 or the second wire bending guide 1172c-13 may be captured. After capturing the coil wire, the coil winding machine may press the coil wire into the wire guide groove 1172c-09.

[0109] Wire guide head that does not catch coil wire

[0110] Figure 13 and Figure 14 An alternative bobbin 1372c for low stress coil wire winding is shown. The alternative bobbin 1372c includes a wire guide head that does not capture the coil wire, as discussed in more detail below. Figure 13 and Figure 14 As shown, the bobbin 1372c has a hollow cylindrical shape with respect to the coil bobbin centerline CL. 1372c The bobbin 1372c or wire winding tool can be symmetrical around the coil bobbin centerline CL 1372c Rotated to form a coil similar to coil 276c described above.

[0111] Spool 1372c Figure 13 and Figure 14 1072c-03. 1372c Basically symmetrical.

[0112] The bobbin base 1372c-04 also includes a wire guide head 1372c-05 extending radially from the bobbin base 1372c-04. The wire guide head 1372c-05 can be used to wind the coil wire around the bobbin 1372c in the coil groove 1372c-03. Figure 13 and Figure 14 As can be appreciated, the wire guide head 1372c-05 extends radially from the peripheral surface of the bobbin base 1372c-04. The bobbin base 1372c-04 is shown as having a cylindrical shape with a base chamfered surface 1372c-06. As can be seen, the base chamfered surface 1372c-06 extends from the outer portion of the bobbin base 1372c-04 to the coil groove shoulder 1372c-02 at a gradually decreasing radial distance. Thus, the base chamfered surface 1372c-06 forms an inclined surface or ramped surface extending toward the coil groove 1372c-03.

[0113] like Figure 13 and Figure 14As shown, the wire guide head 1372c-05 includes a first wire winding guide 1372c-07 and a second wire winding guide 1372c-08. The first wire winding guide 1372c-07 and the second wire winding guide 1372c-08 can be an inlet wire winding guide and an outlet wire winding guide, respectively, but any suitable arrangement and / or terminology can be used. The first wire winding guide 1372c-07 and the second wire winding guide 1372c-08 can capture the coil wire in the circumferential direction and restrain the coil wire during winding around the bobbin 1372c.

[0114] exist Figure 13 and Figure 14 , the first wire winding guide 1372c-07 and the second wire winding guide 1372c-08 are shown as including a first wire guide groove 1372c-09 and a first wire bend guide 1372c-10, as well as a second wire guide groove 1372c-12 and a second wire bend guide 1372c-13, respectively. A wire guide backing 1372c-11 is provided between the first wire bend guide 1372c-10 and the second wire bend guide 1372c-13. The first wire guide groove 1372c-09 is located between the first wire bend guide 1372c-10 and the wire guide backing 1372c-11 and is at least partially defined by the first wire bend guide 1372c-10 and the wire guide backing 1372c-11. Similarly, the second wire guide groove 1372c-12 is located between and at least partially defined by the second wire bend guide 1372c-13 and the wire guide backing 1372c-11.

[0115] like Figure 13 and Figure 14 As shown, first wire guide groove 1372c-09 includes first wire guide inner wall 1372c-14, first wire guide slope 1372c-16, and first wire guide outer wall 1372c-15. Similarly, second wire guide groove 1372c-12 includes second wire guide inner wall 1372c-17, second wire guide slope 1372c-19, and second wire guide outer wall 1372c-18. As can be understood, first wire guide inner wall 1372c-14 and second wire guide inner wall 1372c-17, first wire guide slope 1372c-16 and second wire guide slope 1372c-19, and first wire guide outer wall 1372c-15 and second wire guide outer wall 1372c-18 are formed of curved surfaces.

[0116] For example, the first wire guide outer wall 1372c-15 and the second wire guide outer wall 1372c-18 include symmetrical arcs that curve from the outer portion of the wire guide head 1372c-05 to the coil groove shoulder 1372c-02. Near the outer portion of the wire guide head 1372c-05, the first wire guide outer wall 1372c-15 and the second wire guide outer wall 1372c-18 curve from a direction approximately perpendicular to the plane formed by the outer portion of the wire guide head 1373 to a direction approximately parallel to the coil groove shoulder 1372c-02. The arcuate shapes of the first and second wire guide outer walls 1372c-15 and 1372c-18 do not have a constant radius of curvature, but rather have a radius of curvature that gradually increases as the first and second wire guide outer walls 1372c-15 and 1372c-18 extend from the outer portion of the wire guide head 1372c-05.

[0117] As can also be seen, the first wire guide outer wall 1372c-15 and the second wire guide outer wall 1372c-18 have significant lengths. For example, the lengths of the first wire guide outer wall 1372c-15 and the second wire guide outer wall 1372c-18 are several times greater than the widths of the first wire guide slope 1372c-16 and the second wire guide slope 1372c-19. Consequently, the lengths of the first wire guide outer wall 1372c-15 and the second wire guide outer wall 1372c-18 are several times greater than the width of the coil wire guided by the first wire guide groove 1372c-09 and the second wire guide groove 1372c-12.

[0118] As from Figure 13 and Figure 14 As can be appreciated, the wire guide backing 1372c-11 extends from the spool base 1372c-04 as much as the first wire bend guide 1372c-10 and the second wire bend guide 1372c-13. More specifically, the wire guide backing 1372c-11 does not include a chamfered portion near the coil groove shoulder 1372c-02 that is the same radial distance as the base chamfered surface 1372c-06. Furthermore, near the coil groove shoulder 1372c-02, the first wire bend guide 1372c-10 and the second wire bend guide 1372c-13 include a chamfered portion that extends from the spool base 1372c-04 the same distance as the chamfered portion of the wire guide backing 1372c-11.

[0119] Therefore, during winding, as the coil wire winds around the coil bobbin centerline CL 1372c When circumferentially displaced, the longitudinal direction (eg, substantially parallel to the coil bobbin centerline CL) between the first wire bending guide 1372c-10 and the second wire bending guide 1372c-13 is substantially parallel to the coil bobbin centerline CL.1372c ) The coil wire extending from the first wire bend guide 1372c-10 or the second wire bend guide 1372c-13 may not necessarily be caught by the first wire bend guide 1372c-10 or the second wire bend guide 1372c-13. Instead, the wire winding machine may press the coil wire into the first wire guide groove 1372c-09 or the second wire guide groove 1372c-12 before winding.

[0120] Characteristics of bobbins for low-stress coil wire winding

[0121] As previously described, the bobbins 272c, 1072c, 1172c, 1372c for low-stress coil wire winding can include coil grooves 272c-03, 1072c-03, 1172c-03, 1372c-03 extending between the proximal and distal ends of the bobbins 272c, 1072c, 1172c, 1372c. The proximal ends can be near the location where the coil winding machine allows the coil wire to enter and exit the bobbins 272c, 1072c, 1172c, 1372c, respectively. The distal ends of the bobbins 272c, 1072c, 1172c, 1372c can be away from the location where the coil winding machine allows the coil wire to enter and exit the bobbins.

[0122] The spool 272c, 1072c, 1172c, 1372c may also include a wire guiding head 272c-05, 1072c-05, 1172c-05, 1372c-05 at the proximal end. The wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-05 may include one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12, which extend through the wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-05 to the coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03. One or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 are curved. Because one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 are curved, the coil wire disposed in the wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 will not be subjected to significant stress. For example, the coil wire will not have a 90 degree bend under tension during or after coil wire winding.

[0123] The curved one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 may include one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 extending from the outer end of the wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-15 in a substantially continuous curve to the coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03. That is, one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 do not include, for example, a 90-degree corner. The curve of one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 can be in a radial direction (e.g., orthogonal to the coil bobbin centerline CL). 272c , CL 1072c , CL 1172c , CL 1372c ) and / or circumferential direction (eg, around the coil bobbin centerline CL 272c , CL 1072c , CL 1172c , CL 1372c In addition, the curvilinear one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 may include ends of the one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 that are substantially parallel to surfaces at outer portions of, for example, the bobbin base 272c-04, 1072c-04, 1172c-04, 1372c-04 and the coil grooves 272c-03, 1072c-03, 1172c-03, 1372c-03.

[0124] The coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03 extending between the proximal end and the distal end may include a coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03 extending between a coil groove lip 272c-01, 1072c-01, 1172c-01, 1372c-01 at the distal end of the bobbin 272c, 1072c, 1172c, 1372c and a coil groove shoulder 272c-02, 1072c-02, 1172c-02, 1372c-02 at the proximal end of the bobbin 272c, 1072c, 1172c, 1372c. For example, the radial distance between the coil groove lip 272c-01, 1072c-01, 1172c-01, 1372c-01 at the distal end of the bobbin 272c, 1072c, 1172c, 1372c can be substantially equal to the radial distance between the coil groove shoulder 272c-02, 1072c-02, 1172c-02, 1372c-02 at the proximal end of the bobbin 272c, 1072c, 1172c, 1372c. Additionally or alternatively, the radial distance between the wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-05 can be greater than the radial distance between the coil groove shoulder 272c-02, 1072c-02, 1172c-02, 1372c-02. The wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-05 may further include a wire guide head chamfer extending from a radial distance of the wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-05 to a radial distance of the coil groove shoulder 272c-02, 1072c-02, 1172c-02, 1372c-02.

[0125] One or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 extending through the wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-05 to the coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03 may include a wire guide groove 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12. The radial distance of the leader section 272c-05, 1072c-05, 1172c-05, 1372c-05 is radially inclined to the radial distance of the coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03, one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12. Additionally or alternatively, one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-03 may extend through the wire guide head 272c-05, 1072c-05, 1172c-05, 1372c-05 to the coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03. 72c-12 may include one or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 that bend circumferentially from the proximal end of the spool 272c, 1072c, 1172c, 1372c to the coil groove 272c-03, 1072c-03, 1172c-03, 1372c-03.

[0126] One or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 may include a wire guide bevel 272c-16, 272c-19, 1072c-16, 1072c-19, 1172c-16, 1372c-16, 1372c-19. The radial distance of the wire guiding heads 272c-05, 1072c-05, 1172c-05, 1372c-05 includes the radial distance of the wire guiding slopes 272c-16, 272c-19, 1072c-16, 1072c-19, 1172c-16, 1372c-16, 1372c-19. One or more wire guide grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12 may include wire guide inner walls 272c-14, 272c-17, 1072c-14, 1072c-17, 1372c-14, 1372c-17 and / or wire guide outer walls 272c-15, 272c-18, 1072c-15, 1072c-18, 1172c-15, 1172c-18, 1372c-15, 1372c-18. Wire guide outer wall 272c-15,272c-18,1072c-15,1072c-18,1172c-15,1172c-18,1372c-15,1372c-18 is configured to keep coil wire and make coil wire bend.As can be appreciated, alternative one or more wire guide grooves can comprise single wire guide groove.For example, alternative bobbin can not comprise wire guide backing.Therefore, single wire guide groove can extend between first wire guide wall and second wire guide wall, and can not comprise inner guide wall.

[0127] The wire guiding head 272c-05, 1072c-05, 1172c-05, 1372c-05 may include a first wire bending guide portion 272c-10, 1072c-10, 1172c-10, 1372c-10 and a second wire bending guide portion 272c-13, 1072c-13, 1172c-13, 1372c-13. The first wire bending guide 272c-10, 1072c-10, 1172c-10, 1372c-10 and the second wire bending guide 272c-13, 1072c-13, 1172c-13, 1372c-13 respectively include one or more wire guiding grooves 272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12. The first wire bend guide 272c-10, 1072c-10, 1172c-10, 1372c-10 and the second wire bend guide 272c-13, 1072c-13, 1172c-13, 1372c-13 can have a radial distance greater than a radial distance of the wire guide backing 272c-11, 1072c-11, 1372c-11, which is disposed between the first wire bend guide 272c-10, 1072c-10, 1172c-10, 1372c-10 and the second wire bend guide 272c-13, 1072c-13, 1172c-13, 1372c-13.

[0128] As can be appreciated, the benefits of the bobbins 272c, 1070, 1172c, 1372c can be realized when the coil wire is wound around the bobbins 272c, 1072c, 1172c, 1372c. An exemplary method of such coil wire winding is described below.

[0129] Coil wire winding method

[0130] Figure 15 A method 1500 of forming a bobbin for low stress coil wire winding is shown. Figure 15As shown, in step 1510, method 1500 forms a coil groove extending between the proximal end and the distal end of the bobbin. The bobbin can be the above-mentioned bobbin 272c, 1072c, 1172c, 1372c, but any suitable bobbin can be adopted. When forming the coil groove, the bobbin can only be partially formed, but can still be referred to as a bobbin. In step 1520, method 1500 forms a wire guide head at the proximal end, wherein forming the wire guide head includes forming one or more wire guide grooves extending through the wire guide head to the coil groove. The one or more wire guide grooves can be curved. That is, for example, one or more grooves can be radially inclined from the radial distance of the outer portion of the wire guide head to the radial distance of the coil groove.

[0131] In step 1510, the coil groove extending between the proximal end and the distal end can include a coil groove extending between a coil groove lip formed at the distal end of the bobbin and a coil groove shoulder at the proximal end of the bobbin. The radial distance between the coil groove lip at the distal end of the bobbin and the radial distance between the coil groove shoulder at the proximal end of the bobbin can be substantially equal. Additionally or alternatively, the radial distance of the wire guide head can be greater than the radial distance of the coil groove shoulder.

[0132] The wire guide head may include a wire guide head chamfer extending from a radial distance of the wire guide head to a radial distance of the coil groove shoulder. The wire guide head chamfer ensures that the coil wire is not subjected to lateral stress or deformation, wear, misalignment, or displacement due to the wire guide head while the coil wire is wound around the spool into the coil groove. Consequently, the coil wire is not subjected to undesirable deformation, breakage, fatigue, or the like.

[0133] In step 1520, forming one or more wire guide grooves extending through the wire guide head to the coil groove may include forming one or more wire guide grooves that are radially inclined from the radial distance of the wire guide head to the radial distance of the coil groove. Additionally or alternatively, forming one or more wire guide grooves extending through the wire guide head to the coil groove may include forming one or more wire guide grooves that are bent along the circumference from the proximal end of the bobbin to the coil groove. Additionally or alternatively, in step 1520, forming one or more wire guide grooves may include forming a wire guide slope, wherein the radial distance of the wire guide head includes the radial distance of the wire guide slope. Additionally or alternatively, forming one or more wire guide grooves may include forming a wire guide inner wall and / or a wire guide outer wall, the wire guide outer wall being configured to hold the coil wire and bend the coil wire. For example, the wire guide outer wall may be bent along the circumference from the outer portion of the wire guide head to the coil groove shoulder.

[0134] Forming the wire guide head portion can include forming a first wire bend guide portion and a second wire bend guide portion, wherein the first wire bend guide portion and the second wire bend guide portion can each include one of the one or more wire guide grooves. Additionally or alternatively, the first wire bend guide portion and the second wire bend guide portion can have a radial distance greater than a radial distance of a wire guide backing disposed between the first wire bend guide portion and the second wire bend guide portion.

[0135] As can be appreciated, bobbins, such as the bobbins 272c, 1072c, 1172c, 1372c described above, are used during assembly of the coil assembly 270c. For example, the bobbins can be configured for low-stress coil wire winding. Figure 16 An exemplary method of describing such an assembly.

[0136] Figure 16 A method 1600 of forming a coil transducer including a bobbin for winding low-stress coil wire is shown. In step 1610, the method 1600 may be configured to generate a low-stress coil wire according to the reference Figure 15 The described method 1500 provides a bobbin. In step 1620, method 1600 sets the coil wire in one of the one or more wire guide grooves of the bobbin. In step 1630, method 1600 winds the coil wire around the bobbin and into the coil groove. Thus, a coil, such as coil 276c described above, can be formed. Because the bobbin is provided by method 1500 and therefore includes a curved wire guide groove, the coil wire set in one of the one or more wire guide grooves according to method 1600 can be curved. Curved coil wire can be defined as a coil wire having only one or more following bends: the radius of the bend is greater than or significantly greater than the radius of the coil wire. Therefore, a curved coil wire can also be defined by a coil wire without the following bends: the radius of the bend is approximately or less than the radius of the coil wire. Method 1600 may further include disposing the coil wire in another one of the one or more wire guide grooves, wherein the coil wire in the other one of the one or more wire guide grooves is curvilinear.

[0137] The bobbins 272c, 1072c, 1172c, 1372c and methods 1500, 1600 described above can be used for low-stress coil wire winding. For example, the bobbins 272c, 1072c, 1172c, 1372c include one or more curved wire guide grooves. Therefore, corners or other sharp features do not exert lateral forces on the coil wire, thereby avoiding bending or curvature of the coil wire. This can reduce localized stress in the coil wire, thereby ensuring that the coil wire does not fail during winding. In addition, due to the relatively low stress in the coil wire and the resulting lack of strain, the mechanical and electrical properties of the coil wire can remain unchanged after winding. For example, the cross-sectional area of ​​the coil wire can remain the same after winding the coil wire around the bobbin. As a result, electrical properties, such as resistance, can remain unchanged. In addition or alternatively, mechanical properties can also remain unchanged, allowing for consistent thermal properties, such as consistent thermal expansion of the coil wire. This ensures that electrical performance remains predictable after the coil wire is wound.

[0138] The detailed description of the above embodiments is not an exhaustive description of all embodiments contemplated by the inventors to fall within the scope of this specification. Indeed, those skilled in the art will recognize that certain elements of the above-described embodiments may be variously combined or eliminated to create additional embodiments, and such additional embodiments fall within the scope and teachings of this specification. It will also be apparent to those skilled in the art that the above-described embodiments may be combined in whole or in part to create additional embodiments within the scope and teachings of this specification.

[0139] Therefore, although specific embodiments are described herein for illustrative purposes, various equivalent modifications are possible within the scope of this specification, as those skilled in the relevant art will recognize. The teachings provided herein can be applied to other bobbins for winding low-stress coil wire. Therefore, the scope of the above-described embodiments should be determined by the appended claims.

Claims

1. A bobbin (272c, 1072c, 1172c, 1372c) for winding a low-stress coil wire, the bobbin comprising: a coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03) extending between a proximal end and a distal end of the bobbin (272c, 1072c, 1172c, 1372c); and A wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) is located at the proximal end, and the wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) includes a wire guide head (2 one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12) extending from the coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03); Wherein, the one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12) are curved.

2. The spool (272c, 1072c, 1172c, 1372c) of claim 1, wherein The coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03) extending between the proximal end and the distal end includes a coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03) extending between a coil groove lip (272c-01, 1072c-01, 1172c-01, 1372c-01) at the distal end of the bobbin (272c, 1072c, 1172c, 1372c) and a coil groove shoulder (272c-02, 1072c-02, 1172c-02, 1372c-02) at the proximal end of the bobbin (272c, 1072c, 1172c, 1372c).

3. The spool (272c, 1072c, 1172c, 1372c) of claim 2, wherein The radial distance of the coil groove lip (272c-01, 1072c-01, 1172c-01, 1372c-01) located at the distal end of the bobbin (272c, 1072c) is substantially equal to the radial distance of the coil groove shoulder (272c-02, 1072c-02, 1172c-02, 1372c-02) located at the proximal end of the bobbin (272c, 1072c, 1172c, 1372c).

4. The spool (272c, 1072c, 1172c, 1372c) of claim 3, wherein The radial distance of the wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) is greater than the radial distance of the coil groove shoulder (272c-02, 1072c-02, 1172c-02, 1372c-02).

5. The spool (272c, 1072c, 1172c, 1372c) of claim 4, wherein The wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) includes a wire guide head chamfered portion, which extends from the radial distance of the wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) to the radial distance of the coil groove shoulder (272c-02, 1072c-02, 1172c-02, 1372c-02).

6. The spool (272c, 1072c, 1172c, 1372c) of one of the preceding claims 1 to 5, wherein The one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12) extending through the wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) to the coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03) include at least one of the following: the one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12) being radially inclined from a radial distance of the wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) to a radial distance of the coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03); and The one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12) are bent along the periphery from the proximal end of the bobbin (272c, 1072c, 1172c, 1372c) to the coil groove (272c-03, 1072c-03, 1172c-03, 1372c-03).

7. The spool (272c, 1072c, 1172c, 1372c) of claim 6, wherein The one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12) include wire guide slopes (272c-16, 272c-19, 1072c-16, 1072c-19, 1172c-16, 1372c-16, 1372c-12) 72c-19), wherein the radial distance of the wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) includes the radial distance of the wire guide slope (272c-16, 272c-19, 1072c-16, 1072c-19, 1172c-16, 1372c-16, 1372c-19).

8. The spool (272c, 1072c, 1172c, 1372c) of claim 6, wherein The one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12) include wire guide inner walls (272c-14, 272c-17, 1072c-14, 1072c-17, 1372c-14, 1372c-17) and wire guides At least one of the outer walls (272c-15, 272c-18, 1072c-15, 1072c-18), the wire guiding outer walls (272c-15, 272c-18, 1072c-15, 1072c-18, 1172c-15, 1172c-18, 1372c-15, 1372c-18) being configured to hold and bend the coil wire.

9. The spool (272c, 1072c, 1172c, 1372c) of one of the preceding claims 1 to 8, wherein The wire guide head (272c-05, 1072c-05, 1172c-05, 1372c-05) includes a first wire bending guide portion (272c-10, 1072c-10, 1172c-10, 1372c-10) and a second wire bending guide portion (272c-13, 1072c-13, 1172c-13, 1372c-13), wherein the first wire bending guide portion (272c-10, 1 072c-10, 1172c-10, 1372c-10) and the second wire bending guide portion (272c-13, 1072c-13, 1172c-13, 1372c-13) respectively include one of the one or more wire guide grooves (272c-09, 272c-12, 1072c-09, 1072c-12, 1172c-09, 1372c-09, 1372c-12).

10. The spool (272c, 1072c, 1172c, 1372c) of claim 9, wherein The first wire bend guide (272c-10, 1072c-10, 1172c-10, 1372c-10) and the second wire bend guide (272c-13, 1072c-13, 1172c-13, 1372c-13) have a radial distance that is greater than a radial distance of a wire guide backing (272c-11, 1072c-11, 1172c-11, 1372c-11) disposed between the first wire bend guide (272c-10, 1072c-10, 1172c-10, 1372c-10) and the second wire bend guide (272c-13, 1072c-13, 1172c-13, 1372c-13).

11. A coil transducer (270), the coil transducer (270) having a bobbin for winding a low-stress coil wire, the coil transducer (270) comprising: Magnet assembly (270m); as well as A coil assembly (270c), the coil assembly (270c) comprising: Coil (276c); as well as The bobbin (272c, 1072c, 1172c, 1372c) of one of the preceding claims 1 to 10, the bobbin (272c, 1072c, 1172c, 1372c) being arranged within the coil (276c).

12. A sensor assembly (10) having a bobbin for winding low-stress coil wire, the sensor assembly (10) comprising: a catheter (130); relative ontology; as well as The coil transducer (270) of claim 11, the coil transducer (270) being mechanically coupled to the catheter (130) and the opposing body.

13. The sensor assembly (10) according to claim 12, wherein The opposing body includes one of a guide tube (130'), a reference body, and a balance pole.

14. A method of forming a bobbin for low-stress coil wire winding, the method comprising: forming a coil groove extending between the proximal and distal ends of the bobbin; as well as forming a wire guiding head at the proximal end, wherein forming the wire guiding head includes forming one or more wire guiding grooves extending through the wire guiding head to the coil groove; Wherein, the one or more wire guiding grooves are curved.

15. The method according to claim 14, wherein A coil groove formed extending between the proximal and distal ends of the bobbin includes a coil groove formed between a coil groove lip at the distal end of the bobbin and a coil groove shoulder at the proximal end of the bobbin.

16. The method according to claim 15, wherein The radial distance of the coil groove lip at the distal end of the bobbin is substantially equal to the radial distance of the coil groove shoulder at the proximal end of the bobbin.

17. The method according to claim 16, wherein The radial distance of the wire guide head is greater than the radial distance of the coil groove shoulder.

18. The method according to claim 17, wherein: The wire guiding head includes a wire guiding head chamfer extending from the radial distance of the wire guiding head to the radial distance of the coil groove shoulder.

19. The method according to one of the preceding claims 14 to 18, wherein Forming the one or more wire guide grooves extending through the wire guide head to the coil groove includes at least one of the following: forming the one or more wire guide grooves radially inclined from the radial distance of the wire guide head to the radial distance of the coil groove; and The one or more wire guide grooves are formed to bend circumferentially from the proximal end of the bobbin to the coil groove.

20. The method according to claim 19, wherein Forming the one or more wire guiding grooves includes forming a wire guiding bevel, wherein the radial distance of the wire guiding head includes a radial distance of the wire guiding bevel.

21. The method according to claim 20, wherein Forming the one or more wire guide grooves includes forming at least one of a wire guide inner wall and a wire guide outer wall configured to hold and bend the coil wire.

22. The method according to one of the preceding claims 14 to 21, wherein Forming the wire guiding head portion includes forming a first wire bend guide portion and a second wire bend guide portion, each of the first wire bend guide portion and the second wire bend guide portion including one of the one or more wire guiding grooves.

23. The method according to claim 22, wherein The first and second wire bend guides have a radial distance greater than a radial distance of a wire guide backing disposed therebetween.

24. A method of forming a coil transducer, the method comprising: Providing a spool according to one of the preceding claims 14 to 22; as well as placing a coil wire in one of the one or more wire guide grooves; as well as winding the coil wire around the bobbin and into the coil groove; Wherein, the coil wire is curved in the one of the one or more wire guide grooves.

25. The method of claim 24, further comprising disposing the coil wire in another one of the one or more wire guide grooves, wherein The coil wire is curvilinear in the other one of the one or more wire guide grooves.

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