Infiltration of material into coils

Abstract

A coil bobbin (220cb, 1020cb) for infiltrating a winding of material into a coil (220cc) is provided. The coil bobbin (220cb, 1020cb) includes: a bobbin base portion (225cb, 1025cb); a bobbin lip (226cb, 1026cb); and a coil groove (224cb, 1024cb), the coil groove (224cb, 1024cb) extending between the bobbin base (225cb, 1025cb) and the bobbin lip (226cb, 1026cb). The coil groove (224cb, 1024cb) includes one or more bobbin openings (227cb, 1027cb), the one or more bobbin openings (227cb, 1027cb) being configured to apply a pressure difference to the coil groove (224cb, 1024cb).

Description

Technical Field

[0001] The embodiments described below relate to coil transducers, and more specifically, to permeating material into coils. Background Technology

[0002] A coil transducer typically comprises a coil wire wound around a spool having a hollow interior. A magnet moves in and out of the hollow interior of the spool to generate an electric current in the coil wire. The magnitude of the current is proportional to the speed of the magnet and the strength of the magnetic field supplied 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 to induce opposing forces on the coil wire and the magnet. Therefore, a coil transducer can be used to convert electrical signals into mechanical forces and / or mechanical speeds into electrical signals. The magnet and coil spool assembly can be referred to as a coil transducer component, and the mechanical force and / or speed can be referred to as mechanical motion.

[0003] As is understandable, coil transducers may require accurate and repeatable conversion of mechanical motion into electrical signals and vice versa. Furthermore, unit-to-unit consistency is desirable for the reliability of calibration, measurement, maintenance, etc. For example, current can have a substantially linear relationship with mechanical force. However, the accuracy, repeatability, and unit-to-unit consistency of linearity may depend on the specifications and related characteristics of the coil wire dimensions, such as coil wire spacing and the insulation surrounding the coil wire.

[0004] The coil wire is wound in continuous layers from one flange to another on the hub of a spool, typically two to ten layers per coil. A perfectly wound spool will cause each successive layer to offset the wire radius, allowing each layer to rest in the valley formed by the adjacent loops in the previous layer. Variations in many factors, including wire diameter, spool size, wire tension, and the precision of the winding machine control, collectively create gaps and overlaps in the continuous wire loops. The outer layer of the coil wire is coated with a polymer, cement, or cement / polymer mixture to confine any loose wire segments. Numerous attempts have been made to penetrate the coil winding with polymer, cement, or cement / polymer mixture to confine the internal length of the wire. Attempted coating methods include impregnation, wet winding, and applying the outer layer with a brush or knife. No attempted method has resulted in uniformly filled gaps between the wires throughout all layers of the coil.

[0005] Therefore, a spool is needed to uniformly fill the gaps between the turns of the coil. Consequently, it is necessary to permeate the coil with material. Summary of the Invention

[0006] A coil spool is provided for winding material into a coil. According to one embodiment, the coil spool includes: a spool base; a spool lip; and a coil groove extending between the spool base and the spool lip. The coil groove includes one or more spool openings configured to apply a pressure differential to the coil groove.

[0007] A coil transducer is provided, comprising a coil-permeable material in a coil. According to an embodiment, the coil transducer includes: a coil spool provided as described above; a coil disposed in a coil recess extending between a base of the spool and a lip of the spool; and a coil-permeable material disposed between windings of the coil, the coil-permeable material being substantially void-free.

[0008] A vibration device is provided. According to an embodiment, the vibration device includes: a vibration element; and a coil transducer formed as described above, the coil transducer being attached to the vibration element.

[0009] A method is provided for forming a spool for permeating material into a coil. According to an embodiment, the method includes: forming a spool base; forming a spool lip; forming a coil groove extending between the spool base and the spool lip; and forming one or more spool openings in the coil groove to allow a pressure differential to be applied to the coil groove.

[0010] A method is provided for forming a coil assembly by permeating material into a coil. According to an embodiment, the method includes: providing a coil spool as described above; winding coil wire around a coil groove on the coil spool; and applying a pressure difference across one or more spool openings in the coil groove.

[0011] A tool for permeating material into a coil is provided. According to an embodiment, the tool includes a material application device configured to supply a permeating material to the coil under pressure from a pressure difference forming a coil groove across a coil spool opening.

[0012] A system for permeating material into a coil is provided. According to one embodiment, the system includes: the tool described above; and a pump configured to supply the permeating material to the tool under pressure from a pressure differential forming one or more spool openings across a coil groove.

[0013] aspect

[0014] According to one aspect, a coil spool for winding material into a coil includes: a spool base; a spool lip; and a coil groove extending between the spool base and the spool lip. The coil groove includes one or more spool openings configured to apply a pressure differential to the coil groove.

[0015] Preferably, one or more spool openings configured to apply a pressure differential to the coil recess include one or more spool openings configured to allow fluid to enter or exit the coil recess.

[0016] Preferably, one or more spool openings configured to allow fluid to enter or exit the coil recess include one or more spool openings configured to allow permeable material to enter or exit the coil recess.

[0017] Preferably, one or more spool openings configured to allow fluid to enter or exit the coil recess include one or more spool openings configured to allow non-permeable materials to enter or exit the coil recess.

[0018] Preferably, the non-permeable material includes one of an atmospheric pressure non-permeable material that shifts toward or from the coil groove and a non-atmospheric pressure non-permeable material that shifts toward or from the coil groove.

[0019] Preferably, the coil groove has a radius smaller than the radius of the spool base and the radius of the spool lip.

[0020] Preferably, the coil groove is at least partially defined by the spool base and the spool lip.

[0021] Preferably, one or more spool openings include through holes extending between the surface defining the coil groove and the surface defining the inner hole of the coil spool.

[0022] Preferably, at least one of the one or more spool openings includes a groove extending between the spool base and the spool lip.

[0023] Preferably, the base of the spool further includes at least one coil wire groove extending from the outside of the coil spool to the coil groove.

[0024] According to one aspect, a coil transducer including coil-permeable material in a coil comprises: a coil spool provided as described above; a coil disposed in a coil groove extending between a base of the spool and a lip of the spool; and a coil-permeable material disposed between the windings of the coil, the coil-permeable material being substantially free of voids.

[0025] Preferably, the coil permeation material includes at least one of plastic, cement, rubber, epoxy resin, colloidal silica, sodium silicate, silicone resin, and aluminum silicate.

[0026] According to one aspect, the vibration device includes: a vibration element; and a coil transducer formed as described above, the coil transducer being attached to the vibration element.

[0027] According to one aspect, a method for forming a spool for permeating material into a coil includes: forming a spool base; forming a spool lip; forming a spool groove extending between the spool base and the spool lip; and forming one or more spool openings in the spool groove to allow a pressure differential to be applied to the coil groove.

[0028] Preferably, forming one or more spool openings to allow a pressure differential to be applied to the coil recess includes forming one or more spool openings to allow fluid to enter or exit the coil recess.

[0029] Preferably, forming one or more spool openings to allow fluid to enter or exit the coil recess includes forming one or more spool openings to allow permeable material to enter or exit the coil recess.

[0030] Preferably, forming one or more spool openings to allow fluid to enter or exit the coil recess includes forming one or more spool openings to allow non-permeable materials to enter or exit the coil recess.

[0031] Preferably, the non-permeable material includes one of an atmospheric pressure non-permeable material that shifts toward or from the coil groove and a non-atmospheric pressure non-permeable material that shifts toward or from the coil groove.

[0032] Preferably, the coil groove has a radius smaller than the radius of the spool base and the radius of the spool lip.

[0033] Preferably, the coil groove is at least partially defined by the spool base and the spool lip.

[0034] Preferably, forming one or more spool openings includes a through hole extending between the surface defining the coil recess and the surface defining the inner hole of the coil spool.

[0035] Preferably, forming at least one of the one or more spool openings includes forming a groove extending between the spool base and the spool lip.

[0036] Preferably, forming the spool base further includes forming at least one coil wire groove extending from the outside of the coil spool to the coil groove.

[0037] According to one aspect, a method of forming a coil assembly by permeating material into a coil includes: providing a coil spool as described above; winding coil wire around a coil groove on the coil spool; and applying a pressure difference across one or more spool openings in the coil groove.

[0038] Preferably, the method further includes providing a permeable material to the coil wire wound around the coil groove of the coil spool.

[0039] Preferably, the pressure difference is applied by applying at least one of a negative pressure and a positive pressure to the coil wire wound around the coil groove of the coil spool.

[0040] Preferably, at least one of the negative pressure and positive pressure applied to the coil wire wound around the coil groove of the coil spool is applied to at least one of the outer portion and the inner portion of the coil wire wound around the coil groove of the coil spool.

[0041] Preferably, at least one of the negative pressure and positive pressure applied to the coil wire includes pressure applied to one of the permeable material and the non-permeable material of the coil wire wound around the coil groove.

[0042] Preferably, the permeable material includes at least one of plastics, cement, rubber, epoxy resin, colloidal silica, sodium silicate, silicone resin, and aluminum silicate, and the non-permeable material includes air.

[0043] According to one aspect, the tool for permeating material into a coil includes: a material application device configured to supply a permeating material to the coil under pressure from a pressure difference between one or more spool openings forming a coil groove across a coil spool.

[0044] Preferably, the material application device configured to provide a permeable material to the coil includes a material application device configured to apply a permeable material to the coil.

[0045] Preferably, the pressure that causes the pressure difference between one or more openings of the cross-coil spool is greater than atmospheric pressure.

[0046] Preferably, the material application device configured to provide a permeable material to the coil includes a material application device configured to deposit the permeable material onto the coil.

[0047] Preferably, the material application device configured to deposit a permeable material onto the coil includes a material application device configured to deposit a permeable material at one of atmospheric pressure and a pressure greater than atmospheric pressure.

[0048] Preferably, the material application device includes one of a syringe and a nozzle.

[0049] Preferably, the material application device further includes a sealing surface configured to provide a seal.

[0050] Preferably, the tool further includes a vacuum application device configured to create a pressure difference across one or more spool openings in the coil groove.

[0051] Preferably, the vacuum application device includes a sealing surface configured to provide a seal.

[0052] According to one aspect, a system for permeating material into a coil includes: the aforementioned tool; and a pump configured to supply the permeating material to the tool under pressure from a pressure differential forming one or more spool openings of a coil groove across a coil spool.

[0053] Preferably, the pump is also configured to receive permeable material from the tool.

[0054] Preferably, the system further includes a controller configured to control at least one of the flow rate and pressure of the permeable material supplied to the tool.

[0055] Preferably, the system further includes a vacuum pump configured to provide negative pressure to the tool. Attached Figure Description

[0056] In all the accompanying drawings, the same reference numerals denote the same elements. It should be understood that the drawings are not necessarily drawn to scale.

[0057] Figure 1 A vibration device 5 is shown, which includes a coil transducer connected to a vibration element of the vibration device 5.

[0058] Figure 2 Another vibration device 200 is shown, as shown, the other vibration device 200 is a vibration meter, the other vibration device 200 includes a coil transducer 220 connected to a first vibration element and a second vibration element 210, 210' of the vibration device 200.

[0059] Figure 3 A partial three-dimensional cross-sectional view of the coil transducer 220 is shown.

[0060] Figures 4 to 9 A perspective view, a plan view, and a cross-sectional view of the coil spool 220cb are shown.

[0061] Figure 10 and Figure 11 A perspective view and a plan view of the alternative coil spool 1020cb are shown.

[0062] Figure 12A cross-sectional plan view of the coil assembly 220c is shown, in which the coil spool 220cb and the coil wire 220cw are shown.

[0063] Figure 13 A cross-sectional plan view of the coil assembly 220c is shown, as well as a system 1300 for permeating material into the coil by applying a pressure difference to the coil spool 220cb and the coil wire 220cw.

[0064] Figure 14 An alternative example of the tool 1450 in the system 1400 for permeating material into a coil is shown.

[0065] Figure 15 Another alternative example of the tool 1550 in the system 1500 for permeating material into a coil is shown.

[0066] Figure 16 A method 1600 for forming a coil spool for permeating material into a coil is shown.

[0067] Figure 17 A method 1700 for forming a coil assembly by permeating material into a coil is shown. Detailed Implementation

[0068] Figures 1 to 17 The following description depicts specific examples to teach those skilled in the art how to manufacture and use the best mode of implementation for permeating material into a coil. Some conventional aspects have been simplified or omitted for the purpose of teaching inventive principles. Those skilled in the art will understand variations from these examples that fall within the scope of this specification. It will be understood that the features described below can be combined in various ways to form multiple variations of permeating material into a coil. Therefore, the embodiments described below are not limited to the specific examples described below, but are defined only by the claims and their equivalents.

[0069] Figure 1 A vibration device 5 is shown, which includes a coil transducer connected to a vibrating element. For example... Figure 1 As shown, the vibration device 5 is a vibration meter including sensor assembly 10 and metering electronics 20, but any suitable vibration device, vibration element, electronics, and / or apparatus can be used. Figure 1 As shown, sensor assembly 10 responds to the mass flow rate and density of the process material. Metering electronics 20 are connected to sensor assembly 10 via wire 100 to provide density, mass flow rate, and temperature information, as well as other information, at port 26.

[0070] The sensor assembly 10 includes a pair of manifolds 150 and 150', flanges 103 and 103' with flange necks 110 and 110', a pair of parallel conduits 130 and 130', an actuator 180, a resistance temperature detector (RTD) 190, and a pair of pickup sensors 170l and 170r. Conduits 130 and 130' are vibrating elements, and the actuator 180 and pickup sensors 170l and 170r are transducers. Conduits 130 and 130' have two substantially straight inlet branches 131 and 131' and outlet branches 134 and 134', which converge toward each other at conduit mounting blocks 120 and 120'. Conduits 130 and 130' bend at two symmetrical locations along their length and are substantially parallel throughout their length. Supports 140 and 140' define axes W and W', with each conduit 130, 130' oscillating about axes W and W'. Branches 131, 131' and 134, 134' of conduits 130, 130' are securely attached to conduit mounting blocks 120 and 120', which in turn are securely attached to manifolds 150 and 150'. This provides a continuous, closed material path throughout the sensor assembly 10.

[0071] When flanges 103 and 103' with orifices 102 and 102' are connected to a process line (not shown) carrying the measured process material via inlet end 104 and outlet end 104', the material enters the meter's inlet end 104 through orifice 101 in flange 103 and is guided through manifold 150 to conduit mounting block 120 with surface 121. Within manifold 150, the material is split and routed through conduits 130, 130'. Upon exiting conduits 130, 130', the process material is recombined into a single stream within block 120' with surface 121' and manifold 150', and is subsequently routed to outlet end 104', which is connected to the process line (not shown) via flange 103' with orifice 102'.

[0072] Conduits 130 and 130' are selected and suitably mounted to conduit mounting blocks 120 and 120' so that they have substantially the same mass distribution, moment of inertia, and Young's modulus with respect to the bending axes W--W and W'--W', respectively. These bending axes pass through struts 140 and 140'. Since the Young's modulus of the conduit varies with temperature, and this variation affects the calculation of flow rate and density, an RTD 190 is mounted to conduit 130' to continuously measure the temperature of conduit 130'. The temperature of conduit 130', and therefore the voltage appearing on RTD 190 for a given current passing through it, is controlled by the temperature of the material passing through conduit 130'. In known methods, metering electronics 20 uses the temperature-dependent voltage appearing on RTD 190 to compensate for changes in the elastic modulus of conduits 130 and 130' due to any variations in conduit temperature. RTD 190 is connected to metering electronics 20 via wire 195.

[0073] Both conduits 130 and 130' are driven by actuator 180 in opposite directions about their respective bending axes W and W' and in a so-called first anti-phase bending mode of a vibration meter. The actuator 180 may include any of many known devices, such as a magnet mounted to conduit 130' and an opposing coil mounted to conduit 130, and alternating current flows through this known device to vibrate both conduits 130 and 130'. A suitable drive signal 185 is applied to the actuator 180 via wires through meter electronics 20. Thus, the vibration device 5, or more specifically, the sensor assembly 10, can be considered a symmetrically balanced vibration device.

[0074] Metering electronics 20 receives the RTD temperature signal on wire 195 and sensor signals 165 appearing on wire 100, carrying left sensor signal 165l and right sensor signal 165r respectively. Metering electronics 20 generates a drive signal 185 appearing on the wire leading to driver 180 and causing conduits 130, 130' to vibrate. Metering electronics 20 processes the left sensor signal 165l and right sensor signal 165r, as well as the wire 195 carrying the RTD signal, 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 to port 26 by metering electronics 20.

[0075] As discussed above, sensor assembly 10 includes a driver 180 and a pair of pickup sensors 170l and 170r. The driver 180 and pickup sensors 170l and 170r can be transducers with transducer components. In particular, the driver 180 and pickup sensors 170l, 170r can be coil transducers including coil bobbin assemblies and magnets connected to conduits 130, 130'.

[0076] Figure 2 Another vibration device 200 is shown, as illustrated. This other vibration device 200 is a vibration meter, and includes a coil transducer 220 connected to a first vibration element and a second vibration element 210, 210' of the vibration device 200. Figure 2 As shown, the vibration device 200 includes a first vibration element and second vibration elements 210, 210', which are illustrated as similar to those shown in the reference above. Figure 1 The discussed conduits 130 and 130' are described, but with triangular bends. The vibration device 200 also includes a coil transducer 220 connected to the first and second vibration elements 210 and 210'. The coil transducer 220 can be referenced above. Figure 1 The driver 180 discussed is the same as or similar to the one discussed. However, the coil transducer 220 or an alternative transducer assembly can be used as a pickup sensor. Figure 2 As shown, the vibration device 200 includes a pickup sensor 230 connected to the first vibration element and the second vibration elements 210, 210'. The pickup sensor 230 can be similar to the one described above. Figure 1 The pickup sensors 170l and 170r are discussed. The vibration device 200 also includes inlet and outlet manifolds 240 and 240', as well as a feedthrough 250. The feedthrough 250 can be mechanically and communicatively connected to a junction that accommodates a measuring electronics device that is the same as or similar to the measuring electronics device 20 discussed above. As described in more detail below, the coil transducer 220 can be formed by permeating material into the coil of the coil transducer 220.

[0077] Including coil transducers for permeating materials.

[0078] Figure 3 A partial three-dimensional cross-sectional view of the coil transducer 220 is shown. Figure 3As shown, the coil transducer 220 includes a coil assembly 220c, wherein a corresponding magnet assembly is not shown for clarity. The coil assembly 220c includes spacers 220cs mechanically coupled to a coil spool 220cb. More specifically, the coil spool 220cb is shown as mechanically coupled to the spacers 220cs via a bolt 220ct screwed into a threaded washer 220cf. The bolt 220ct includes an internally threaded portion for mounting the coil transducer 220 to one of the conduits 130, 130'. The bolt 220ct and the threaded washer 220cf apply compressive forces, such as coaxial and / or engagement compressive forces, to the coil spool 220cb and the spacers 220cs. Thus, the bolt 220ct extends through a smooth bolt hole in the coil spool 220cb into a threaded hole in the threaded washer 220cf. The coil spool 220cb and the spacers 220cs are about the centerline CL of the coil transducer. 220 The center line CL is set symmetrically. 220 This can be the longitudinal axis of the coil transducer 220. Although not shown, a threaded mounting post can be inserted into the internal thread of the bolt 220ct to mount the coil transducer 220 to the conduits 130, 130'.

[0079] The spacer 220cs is configured to be mounted to a movable element, such as, for example, the first and second vibrating elements 210, 210' described above, but any suitable movable element can be used. The spacer 220cs can be mounted to the movable element using any suitable method, such as welding, brazing, fastening devices, clamps, etc. The spacer 220cs can be mounted substantially rigidly to the movable element. Therefore, the spacer 220cs can be configured to move in unison with the movable element. As can be understood, since the coil spool 220cb is connected to the spacer 220cs, the coil spool 220cb also moves in unison with the movable element.

[0080] The coil spool 220cb has a substantially cylindrical shape. More specifically, the coil spool 220cb is oriented about the center line CL of the coil transducer. 220Symmetrical. The coil spool 220cb includes a distal end and a proximal end relative to the spacer 220cs. That is, the distal end is furthest from the spacer 220cs, and the proximal end is closest to the spacer 220cs. The coil spool 220cb includes an inner bore 222cb that opens at the distal end of the coil spool 220cb. The inner bore 222cb is defined by an inner cylindrical surface of the coil spool 220cb. The coil spool 220cb also includes a coil groove 224cb extending from the proximal end to the distal end of the coil spool 220cb. The coil groove 224cb is defined by a U-shaped surface extending circumferentially around the coil spool 220cb. A plurality of spool openings 227cb extend through the coil spool 220cb between the U-shaped surface defining the coil groove 224cb and the inner cylindrical surface defining the inner bore 222cb.

[0081] The spool opening 227cb is shown as having a cylindrical groove extending between the proximal and distal ends of the coil spool 220cb, but it can take any suitable shape. For example, the spool opening 227cb may include a circle or other geometry, a curve, a variable-width opening, etc., instead of a groove. Figure 3 As shown, the cylindrical slot is parallel to the center line CL of the coil transducer. 220 It extends completely to the distal end of the coil spool 220cb. In addition, multiple spool openings 227cb are spaced apart from each other at regular intervals.

[0082] like Figure 3 As shown, the coil transducer 220 includes a coil wire 220cw (though not shown) wound around a coil groove 224cb around a coil spool 220cb. Figure 3 The magnet assembly that constructively engages with the coil assembly 220c is also not shown. The magnet assembly may include a magnet holder and a magnet. The magnet holder may be configured to hold the magnet such that when the magnet assembly is along a path that can be aligned with the center line CL of the coil transducer... 220 As the collinear magnet assembly moves along its translational path, the magnet extends into the inner hole 222cb of the coil spool 220cb. The translational path of the magnet assembly can also be substantially coaxial with the longitudinal axis of the coil spool 220cb, which can also be aligned with the center line CL of the coil transducer. 220 Collinear. The coil wire 220cw wound around the coil groove 224cb forms a coil 220cc for converting between electrical signals and magnetic fields.

[0083] As will be described in more detail below, a pressure differential can be applied across multiple spool openings 227cb to apply pressure to the penetrating material impacting the windings of the coil wire 220cw. The pressure differential applied to the penetrating material can force the penetrating material to flow between the gaps or voids in the windings of the coil wire 220cw. Thus, the penetrating material can flow and settle in the gaps between the windings of the coil 220cc. As described in more detail below, the penetrating material can be “pushed” and / or “pulled” by the pressure differential applied across the multiple spool openings 227cb, and the penetrating material may or may not traverse the multiple spool openings 227cb. Therefore, a pressure differential can be applied to the penetrating material impacting the outermost winding or the innermost winding of the coil wire 220cw.

[0084] Coil spools used to permeate material into coils

[0085] Figures 4 to 9 A perspective view, a plan view, and a cross-sectional view of the coil spool 220cb are shown. (See diagram.) Figures 4 to 9 As shown, the coil spool 220cb includes an inner hole 222cb and a coil recess 224cb. The coil recess 224cb is partially defined by a spool base 225cb and a spool lip 226cb. Additionally, the coil recess 224cb is defined by a surface extending between the spool base 225cb and the spool lip 226cb. The coil spool 220cb, or more specifically, the coil recess 224cb, includes a plurality of spool openings 227cb. As can be understood, the spool openings 227cb have a parallel line CL to the centerline of the coil transducer. 220 A longitudinal and linear profile extends from the base 225cb of the spool to the lip 226cb of the spool. Multiple spool openings 227cb also extend through the coil spool 220cb between the surface of the coil recess 224cb and the surface of the inner hole 222cb.

[0086] If it is still possible Figures 4 to 9 As seen in the image, multiple spool openings, 227cb winding coil transducer centerline CL 220 They are arranged symmetrically at regular intervals. More specifically, the multiple spool openings 227cb include those parallel to the center line CL of the coil transducer. 220 And relative to the center line CL of the coil transducer 220 The longitudinal length is equidistant. Multiple spool openings 227cb are also equidistant from adjacent spool openings 227cb. That is, the multiple spool openings 227cb are arranged along the surface defining the coil recess 224cb and aligned with the coil transducer centerline CL. 220 Orthogonal circumferential distances are equally spaced from each other. For example, it can also be seen from... Figures 4 to 9Understood, there are six equally spaced spool openings 227cb extending between the inner bore 222cb and the coil recess 224cb, but any suitable number and / or arrangement can be used. Additionally or alternatively, other spool openings can have different shapes, locations, etc. For example, other spool openings may include curves, waves, corners, and / or openings with various geometric cross-sections at the side profile and / or through the spool. For example, as... Figures 4 to 9 As shown, the spool opening 227cb is illustrated as having a line parallel to the center line CL of the coil transducer. 220 The extended plane's circumferential profile is illustrated relative to the coil transducer centerline CL. 220 A rectangular cross-sectional opening extending orthogonally and collinearly, but any suitable spool opening can be used.

[0087] If possible Figures 4 to 9 Understood, the coil spool 220cb is substantially symmetrical about the axis. For example, the coil spool 220cb has a symmetrical shape about the center line CL of the coil transducer. 220 The body is essentially symmetrical. More specifically, the inner hole 222cb, the coil groove 224cb, the spool base 225cb, and the spool lip 226cb have a transducer centerline CL around the coil. 220 The cylindrical shape is set. That is, the inner hole 222cb and the spool base 225cb are shown as being formed by the center line CL of the coil transducer. 220 The surface of the cylindrical component is defined. Similarly, the spool base 225cb and spool lip 226cb have a coil transducer centerline CL. 220 The ring-shaped body is set. It can also be... Figures 4 to 9 As seen in the image, the coil spool 220cb also includes a coil wire groove 228cb, which is configured to receive and accommodate the coil wire. Figure 3 The coil wire shown is 220cw. (As...) Figures 4 to 9 As shown, the coil wire groove 228cb has a semi-circular cross-section extending from one side of the coil spool 220cb to the other side of the coil spool 220cb. Two coil wire grooves 228cb are shown. As can be understood, one of the coil wire grooves 228cb can be referred to as the inlet coil wire groove 228cb, and the other coil wire groove 228cb can be referred to as the outlet coil wire groove 228cb. As can be understood, alternative coil spools for permeating material into the coil can be used, one of which is described below.

[0088] Alternative coil spools for permeating material into coils

[0089] Figure 10 and Figure 11 A perspective view and a plan view of the alternative coil spool 1020cb are shown. The alternative coil spool 1020cb can be used in coil transducers similar to the coil transducer 220 described above. Therefore, a coil transducer including the alternative spool 1020cb can be wound with coil wire 220cw. Figure 10 and Figure 11 As shown, the coil spool 1020cb includes an inner hole 1022cb ( Figure 10 The coil spool 1020cb and coil recess 1024cb are partially defined by a spool base 1025cb and a spool lip 1026cb. Additionally, the coil recess 1024cb is defined by a surface extending between the spool base 1025cb and the spool lip 1026cb. The coil spool 1020cb, or more specifically, the coil recess 1024cb, includes a plurality of spool openings 1027cb. As can be understood, the spool openings 1027cb have a parallel line CL to the centerline of the coil transducer. 1020 A longitudinal and linear profile extends from the spool base 1025cb to the spool lip 1026cb. Multiple spool openings 1027cb also extend through the coil spool 1020cb between the surface of the coil recess 1024cb and the surface of the inner hole 1022cb. More specifically, as... Figure 10 and Figure 11 As shown, each spool opening 1027cb includes an opening groove 1027cba and an opening through hole 1027cbb. The opening groove 1027cba has a longitudinal and linear profile extending from the spool base 1025cb to the spool lip 1026cb. The opening through hole 1027cbb extends through the coil spool 1020cb between the surface of the coil groove 1024cb and the surface of the inner hole 1022cb.

[0090] If it is still possible Figure 10 and Figure 11 As seen in the image, multiple spool openings, 1027cb winding coil transducer centerline CL 1020 They are arranged symmetrically at regular intervals. More specifically, the multiple spool openings 1027cb include those parallel to the center line CL of the coil transducer. 1020 And relative to the center line CL of the coil transducer 1020 The longitudinal length is equidistant. Multiple spool openings 1027cb are also equidistant from adjacent spool openings 1027cb. That is, the multiple spool openings 1027cb are arranged along the surface defining the coil recess 1024cb to align with the coil transducer centerline CL. 1020 Orthogonal circumferential distances are equally spaced from each other. For example, it can also be seen from... Figure 10 and Figure 11 Understood, there are four equally spaced spool openings 1027cb extending between the inner hole 1022cb and the coil groove 1024cb, but any suitable number and / or arrangement can be used. Additionally or alternatively, other spool openings can have different shapes, locations, etc. For example, other spool openings may include curves, waves, corners, and / or one or more openings of various geometric cross-sections located on the side profile and / or through the spool. For example, as... Figure 10 and Figure 11 As shown, the spool opening 1027cb, or more specifically, the opening groove 1027cba, is illustrated as having a shape parallel to the coil transducer centerline CL. 1020 The extended plane's circumferential profile is illustrated relative to the coil transducer centerline CL. 1020 A rectangular cross-sectional opening extending orthogonally and collinearly, but any suitable spool opening can be used.

[0091] If possible Figure 10 and Figure 11 Understood, the coil spool 1020cb is substantially symmetrical about the axis. For example, the coil spool 1020cb has a symmetrical shape about the center line CL of the coil transducer. 1020 The body is essentially symmetrical. More specifically, the inner bore 1022cb, the coil groove 1024cb, the spool base 1025cb, and the spool lip 1026cb have a transducer centerline CL wound around the coil. 1020 The cylindrical shape is set. That is, the inner hole 1022cb and the spool base 1025cb are shown as being formed by the center line CL of the coil transducer. 1020 The surface of the cylindrical component is defined. Similarly, the spool base 1025cb and spool lip 1026cb have a coil transducer centerline CL. 1020 The ring-shaped body is set. It can also be... Figure 10 and Figure 11 As seen in the image, the coil spool 1020cb also includes a coil wire groove 1028cb, which is configured to receive and accommodate the coil wire. Figure 3 The coil wire shown is 220cw. (As...) Figure 10 and Figure 11 As shown, the coil wire groove 1028cb has a semi-circular cross-section extending from one side of the coil spool 1020cb to the other side of the coil spool 1020cb. A coil wire groove 1028cb is shown.

[0092] As can be understood from the foregoing discussion of coil spools 220cb and 1020cb, machines, tools, or persons can place coil wire 220cw in coil wire grooves 228cb and 1028cb, and wind coil wire 220cw around coil grooves 224cb and 1024cb to form a coil, such as coil 220cc, with voids filled with a permeable material. For example, refer to... Figure 10 and Figure 11 The permeable material can flow between the surfaces of the inner bore 1022cb and the coil recess 1024cb. For illustration, the permeable material can be applied via a tool through the inner bore 1022cb to a plurality of open through-holes 1027cbb. The permeable material can flow from the tool and / or the surface of the inner bore 1022cb, flow through the coil spool 1020cb, and flow into the open recess 1027cba. The permeable material can flow into the open recess 1027cba and at least partially fill the open recess 1027cba and / or flow into a coil (not shown) disposed in the coil recess 1024cb. The tool can be a cylindrical tool having two common O-rings inserted into the inner bore 1022cb, sealing against the inner bore 1022cb and allowing the permeable material to flow into the coil recess 1024cb. The permeable material can then flow along the open recess 1027cba and into the coil (not shown). The O-rings on the cylindrical tool can seal the inner hole 1022cb of the spool base 1025cb and the lip side 1026cb of the spool opening 1027cb. The O-rings can each be positioned relative to the coil transducer centerline CL. 1020 It is symmetrical and can have a diameter slightly larger than that of the inner bore 1022cb. The outer diameter of the tool can be slightly smaller than that of the inner bore 1022cb to allow for the filling of the volume between the O-rings.

[0093] The following describes tools and methods that can be used to permeate materials into coils, wherein, reference is made to... Figure 4 and Figure 9 The described coil spool 220cb is used as an exemplary coil spool for permeating material into a coil.

[0094] Coils with permeable material

[0095] Figure 12 A cross-sectional plan view of the coil assembly 220c is shown, in which the coil spool 220cb and coil wire 220cw are shown. Figure 12As shown, the coil spool 220cb includes an inner bore 222cb and a coil recess 224cb. The coil recess 224cb is partially defined by a spool base 225cb and a spool lip 226cb. Additionally, the coil recess 224cb is defined by a surface extending between the spool base 225cb and the spool lip 226cb. The coil spool 220cb, or more specifically, the coil recess 224cb, includes a plurality of spool openings 227cb. As can be understood, the spool openings 227cb have a longitudinal and linear profile extending from the spool base 225cb to the spool lip 226cb. The plurality of spool openings 227cb also extend through the coil spool 220cb between the surface of the coil recess 224cb and the surface of the inner bore 222cb. Although in Figure 12 Not shown, but the coil spool 220cb includes a configuration for receiving and accommodating. Figure 3 The coil wire groove 228cb shown is for the coil wire 220cw (see...). Figure 4 ).like Figure 12 As shown, coil wire 220cw is wound around coil groove 224cb to form coil 220cc, and includes gaps or voids substantially (e.g., reaching or almost entirely, completely, etc.) filled with coil permeation material 220ci. Although in Figure 12 Not shown, but alternative coil bobbin 1020cb can be used in alternative coil assemblies similar to coil assembly 220c. Thus, coil wire 220cw can be wound around coil groove 1024cb to form coil 220cc, and can include gaps or voids substantially (e.g., reaching or almost entirely, completely, etc.) filled with coil permeation material 220ci.

[0096] As will be referred to below Figures 13 to 15 In more detail, the coil permeation material 220ci can be forced between the windings of the coil wire 220cw by employing a pressure difference across multiple spool openings 227cb. The pressure difference can be between the outer region or portion of the coil 220cc and the inner hole 222cb, but any suitable pressure difference can be used. For example, a pressure difference can be applied between the coil wire 220cw and the inner hole 222cb at a location radially spaced from the coil groove 224cb when the coil wire 220cw is first rotated about the coil groove 224cb and subsequently applied between the coil groove 224cb and the inner hole 222cb. The pressure difference can result from the coil permeation material 220ci being applied to the coil 220cc or the inner hole 222cb at a pressure greater than atmospheric pressure, or from a vacuum being applied to the inner hole 222cb or the coil 220cc, as explained in more detail below.

[0097] Systems and tools

[0098] Figure 13 A cross-sectional plan view of the coil assembly 220c is shown, along with a system 1300 for permeating material into the coil by applying a pressure difference to the coil spool 220cb and the coil wire 220cw. Figure 13 The diagram shows a partial depiction of the coil assembly 220c, where only the coil spool 220cb and the coil 220cc are shown. Figure 13 As shown, system 1300 includes pump 1310, which is fluidly connected to reservoir 1320. Pump 1310 is also communicatively connected to controller 1330. Controller 1330 is also shown communicatively connected to vacuum pump 1340. Vacuum pump 1340 is shown in dashed lines to illustrate that it is optional for system 1300, which may or may not utilize an active vacuum to help create a pressure differential on coil assembly 220c. Pump 1310 and vacuum pump 1340 are illustrated as fluidly connected to tool 1350 for applying a permeating material to coil assembly 220c.

[0099] Pump 1310 can be any pump suitable for pumping one or more materials to and / or from tool 1350 via material line 1312. For example, the material pumped by pump 1310 can be a permeable material pumped to tool 1350. Therefore, pump 1310 can be a pump suitable for pumping permeable materials that can cure, for example, upon exposure to atmosphere. In this example, pump 1310 can be a pressure-controlled vessel that externally applies pressure to a large quantity of permeable material. As will be understood, the one or more materials provided by pump 1310 may or may not be permeable materials. As an illustration, pump 1310 can provide, for example, two resins to tool 1350, which are then mixed together to form a permeable material. In either case, pump 1310 can provide the tool, for example... Figure 13 The tool 1350 shown is provided with a permeable material.

[0100] Reservoir 1320 may be one or more containers, conduits, etc., that can provide one or more materials to tool 1350. For example, reservoir 1320 may include a disposable bag disposed inside pump 1310, through which pump 1310 applies the pressure described above to the permeable material. As will be understood, other embodiments may be employed. For example, reservoir 1320 may provide one or more materials to a channel comprising an electroactive material, the channel being turbulent to apply pressure to one or more materials. As will be understood, pump 1310 and reservoir 1320 may be combined in a partially or fully integrated manner. For example, pump 1310 may surround and / or apply pressure to reservoir 1320 to force one or more materials to be extruded into tool 1350. Additionally or alternatively, pump 1310 and / or reservoir 1320 may be integrated into tool 1350.

[0101] Tool 1350 is shown as including proximity to coil assembly 220c or more specifically to coil 220cc (see also) Figure 12 The material application device 1352. As can be understood, the coil 220cc is disposed in the coil groove 224cb of the coil spool 220cb (see Figure 12 (in) . For example Figure 13 As shown, the material application device 1352 is a nozzle that dispenses a penetrating material onto a coil 220cc under atmospheric pressure. The material application device 1352 is shown mechanically coupled to a manifold 1356, which includes a body 1356a and one or more transducers 1356b. The manifold 1356, or more specifically, the body 1356a and one or more transducers 1356b, are configured to be fluidly coupled to a pump 1310 and communicatively coupled to a controller 1330.

[0102] Optional vacuum pump 1340 may be configured to provide negative pressure to tool 1350 via vacuum line 1342 to optional vacuum application device 1354. The term "negative pressure" may be interpreted as a pressure less than the pressure of the permeable material supplied by tool 1350, but any suitable definition may be used. For example, the term "negative pressure" may mean a pressure less than atmospheric pressure. As an addition to or alternative to vacuum pump 1340, negative pressure may be applied by any suitable device that does not involve vacuum pump 1340.

[0103] As discussed above, a pressure differential can be applied across the radial portion of the coil spool 220cb in various ways, which may require tools with specific configurations. The pressure differential can be sufficient to induce flow of penetrating material through the coil, such as the coil 220cc described above. The pressure differential value can be selected to ensure that the penetrating material flows between the windings or gaps of the coil wire 220cw without causing, for example, cavitation. During and / or after the coil wire 220cw is wound around the coil spool 220cb, a pressure differential can be applied across the entire radial distance of the coil, a portion of the radial distance of the coil, all or a portion of the longitudinal distance along the coil, etc. See below. Figure 14 and Figure 15 Two examples are described, but any suitable tool can be used.

[0104] Figure 14 An alternative example of the tool 1450 in the system 1400 for permeating material into a coil is shown. Although Figure 14 Not shown, but system 1400 may include Figure 13 The pump 1310, reservoir 1320, controller 1330, and / or vacuum pump 1340 are shown. Figure 14 The coil assembly 220c described above is used, but any suitable coil assembly can be used. Tool 1450 is shown as including a material application device 1452 near the coil assembly 220c or more specifically near the coil 220cc. As can be understood, the coil 220cc is disposed in the coil groove 224cb of the coil spool 220cb (see...). Figure 12 (in) . For example Figure 14 As shown, the material application device 1452 is a nozzle that dispenses a penetrating material onto the coil 220cc under atmospheric pressure. Therefore, the tool 1450 also includes a vacuum application device 1454, which includes a housing 1454a and a sealing surface 1454b. The vacuum application device 1454 is used to apply material to the inner hole 222cb of the coil spool 220cb (see [reference]). Figure 12 The material application device 1452 is shown as mechanically coupled to a manifold 1456, which includes a body 1456a and one or more transducers 1456b. The manifold 1456, or more specifically the body 1456a and one or more transducers 1456b, is configured to be fluidly coupled to a pump and electrically coupled to a controller, for example, see reference to... Figure 13 Pump 1310 and controller 1330 are described.

[0105] like Figure 14As shown, manifold 1456 is configured to receive two materials from a pump, but may employ more or fewer lines and materials. The two materials may be, for example, resins that react together to form a hardened material, such as epoxy resin. Therefore, manifold 1456 may include a mixer (not shown) configured to mix the two resins into a permeable material. The permeable material may be supplied to material application device 1452. As can be understood, the properties of the permeable material may depend on the ratio of the two materials, the temperature at which the two materials are mixed, the pressure of the two materials, etc. Therefore, one or more transducers 1456b may be configured to convert one or more properties of at least one of the two materials into signals and provide signals representing one or more properties to a controller, which may perform various calculations. As can be understood, any combination of materials including plastics, cement, rubber, epoxy resin, colloidal silica, sodium silicate, silicone resin, aluminum silicate (e.g., hydrated aluminum silicate crystalline minerals, such as kaolin), etc., may be used.

[0106] exist Figure 14 In this embodiment, the vacuum application device 1454 can induce a pressure difference on the coil 220cc. This pressure difference can be the atmospheric pressure outside the coil assembly 220c and the pressure applied by the vacuum application device 1454 to the inner bore 222cb of the coil spool 220cb (see [link to document]). Figure 12 The pressure is between negative pressure and pressure less than atmospheric pressure. Therefore, the penetrating material applied to the coil 220cc by the material application device 1452 can flow between each coil wire turn of the coil 220cc. As can be understood, a negative pressure can be applied after the penetrating material is applied to the coil 220cc. For example, the material application device 1452 and / or the coil assembly 220c can, for example, be around the coil transducer centerline CL. 220 (See) Figure 12 The material application device 1452 rotates relative to each other, allowing it to provide the penetrating material in a substantially uniform manner. After the penetrating material is provided, the vacuum application device 1454 can apply negative pressure to uniformly pull the penetrating material through the coil wire winding of the coil 220cc. Additionally or alternatively, the material application device 1452 may have an annular body surrounding the coil 220cc, thereby allowing the penetrating material to be uniformly applied to the coil assembly 220c with or without rotation of the material application device 1452 and / or the coil assembly 220c.

[0107] Figure 15 Another alternative example of the tool 1550 in the system 1500 for permeating material into a coil is shown. Although Figure 14 Not shown, but system 1500 may include Figure 13The pump 1310, reservoir 1320, controller 1330, and / or vacuum pump 1340 are shown. Figure 15 The coil assembly 220c described above is used, but any suitable coil assembly can be used. Tool 1550 is shown as including a material application device 1552 near the coil assembly 220c or more specifically near the coil 220cc. As can be understood, the coil 220cc is disposed in the coil groove 224cb of the coil spool 220cb (see...). Figure 12 (in) . For example Figure 15 As shown, the material application device 1552 dispenses a penetrating material onto the coil 220cc at a pressure greater than atmospheric pressure. Therefore, the material application device 1552 is shown as including one or more nozzles 1552a and a sealing member 1552b. The tool 1550 also includes a vacuum application device 1554, which includes a housing 1554a and a sealing surface 1554b, for applying material to the inner bore 222cb of the coil spool 220cb (see [reference]). Figure 12 It provides negative pressure. The vacuum application device 1554 is also shown as including one or more transducers 1554c. Figure 14 Conversely, the material application device 1552 is not shown as mechanically connected to the manifold. Fluid is supplied directly to the material application device 1552 without mixing.

[0108] like Figure 15 As shown, the material application device 1552 and the vacuum application device 1554 can apply a pressure difference to the coil recess of the coil assembly 220c. For example, the material application device 1552 can apply a penetrating material to the outer portion of the coil 220cc at a pressure greater than atmospheric pressure, and the vacuum application device 1554 can apply a negative pressure less than atmospheric pressure. Therefore, the pressure difference can be substantially the same as the difference between the pressure of the penetrating material and the negative pressure. The pressure of the fluid can be known from the pump and applied to the inner hole 222cb of the coil spool 220cb (see...). Figure 12 The negative pressure can be known from the vacuum application device 1554. More specifically, one or more transducers 1554c can measure the negative pressure.

[0109] If it is understandable, in Figure 15In this example, negative pressure can be provided by a pump. Therefore, the permeable material can flow through coil 220cc and return to the pump via vacuum application device 1554. The flow of the permeable material through coil 220cc ensures that the permeable material completely fills the gaps between the coil wire windings of coil 220cc. This can be useful for permeating materials that would not otherwise completely fill gaps due to, for example, the presence of particles or relatively high viscosity. Returning the material to the pump also reduces material costs. Therefore, one or more transducers 1554c can measure the properties of the permeable material returning to the pump and provide the measured properties to the controller, allowing the controller to ensure that the permeable material completely fills the spaces or gaps between the coil wire windings of coil 220cc.

[0110] The examples of tools 1350, 1450, and 1550 described above are merely illustrative of possible configurations. Changes and / or combinations can be made to the features described above and other features not explicitly described, based on the expertise of those skilled in the art. For example, vacuum application device 1554 is shown as approximately a spool opening 227cb (see...). Figure 12 The size of a spool opening in the spool. However, it is understood that the vacuum application device 1554 can be considered as representing the size of the spool opening 227cb (see...). Figure 12 The annular shape of all spool openings in the coil 220cc. Additionally or alternatively, the material application device 1552 is shown not covering the entire width of the coil 220cc. Those skilled in the art will understand that users, robots, etc., can apply the material parallel to the coil transducer centerline CL. 1020 The movement of the material application device 1552 causes it to move, so as to uniformly distribute the penetrating material.

[0111] As can be understood, controller 1330 or other controllers may be used to automate some or all of the steps in the application of coil permeation material. A method for forming a coil spool for applying coil permeation material to a coil to form a coil assembly, such as coil spools 220cb, 1020cb and coil assembly 220c described above, is described below.

[0112] Methods for forming coil spools

[0113] Figure 16 A method 1600 for forming a coil spool for permeating material into a coil is shown. (Example) Figure 16As shown, method 1600 begins with step 1610, in which a spool base is formed. In step 1620, method 1600 forms a spool lip. The coil spool can be any suitable coil spool, such as the coil spools 220cb and 1020cb described above. Therefore, the spool base can be a spool base 225cb or 1025cb located at the proximal end of the coil spools 220cb and 1020cb, and the spool lip can be a spool lip 226cb or 1026cb, but any suitable spool base and spool lip can be used. In step 1630, method 1600 forms a coil groove extending between the spool base and the spool lip. The coil groove can be the coil grooves 224cb or 1024cb described above, but any suitable coil groove can be used. In step 1640, method 1600 forms one or more spool openings in the coil recess to allow a pressure differential to be applied to the coil recess.

[0114] Step 1640, which involves forming one or more spool openings to allow a pressure differential to be applied to the coil recess, may include forming one or more spool openings to allow fluid to enter or exit the coil recess. Forming one or more spool openings to allow fluid to enter or exit the coil recess may include forming one or more spool openings to allow a permeable material to enter or exit the coil recess. Additionally or alternatively, forming one or more spool openings to allow fluid to enter or exit the coil recess includes forming one or more spool openings to allow a non-permeable material to enter or exit the coil recess. The non-permeable material includes either an atmospheric pressure non-permeable material that displaces into or from the coil recess, or a non-atmospheric pressure non-permeable material that displaces into or from the coil recess.

[0115] The coil groove includes a radius smaller than the radius of the spool base and the radius of the spool lip. Additionally or alternatively, the coil groove may be at least partially defined by the spool base and the spool lip. As will be understood, forming one or more spool openings may include a through-hole formed between the surface defining the coil groove and the surface defining the inner hole of the coil spool. Additionally or alternatively, forming at least one of the one or more spool openings includes forming a groove formed between the spool base and the spool lip. Forming the spool base may also include forming at least one coil wire groove extending from the outside of the coil spool to the coil groove. The coil wire groove of method 1600 may be the coil wire groove 228cb or 1028cb described above, but any suitable coil wire groove may be used.

[0116] The coil spool formed by method 1600 can be used in coil assemblies, such as the coil assembly 220c described above. A method for forming a coil assembly is described in more detail below.

[0117] Figure 17 A method 1700 for forming a coil assembly by permeating material into the coil is shown. (Example) Figure 17 As shown, in step 1710, method 1700 provides a coil spool. The coil spool can be provided according to the aforementioned method 1600, but any suitable method may be used. In step 1720, method 1700 winds coil wire around the coil grooves of the coil spool. The coil wire can be the coil wire 220cw described above, but any suitable coil wire may be used. In step 1730, method 1700 may apply a pressure differential across one or more spool openings in the coil grooves.

[0118] Method 1700 may further include providing a permeable material to the coil wire wound around the coil groove of the coil spool. A pressure difference may be applied by applying at least one of a negative pressure and a positive pressure to the coil wire wound around the coil groove of the coil spool. At least one of the negative pressure and positive pressure applied to the coil wire wound around the coil groove of the coil spool may be applied to at least one of an outer portion and an inner portion of the coil wire wound around the coil groove of the coil spool. At least one of the negative pressure and positive pressure applied to the coil wire may include pressure applied to either a permeable material or a non-permeable material of the coil wire wound around the coil groove. The permeable material may include at least one of plastics, cement, rubber, epoxy resin, colloidal silica, sodium silicate, silicone resin, aluminum silicate (e.g., hydrated aluminum silicate crystalline minerals, such as kaolin), and the non-permeable material may include air.

[0119] The foregoing describes coil spools 220cb and 1020cb, systems 1300, 1400, and 1500, as well as method 1600 and method 1700 for permeating material into coil 220cc. For example, coil spools 220cb and 1020cb may include spool openings 227cb and 1027cb. A pressure differential may be applied across the spool openings 227cb and 1027cb to force the permeating material into the gaps in the windings of a coil, such as coil 220cc. By forcing the permeating material into the gaps or spaces between the windings of a coil, such as coil 220cc, the coil permeating material can consist entirely of permeating material. Therefore, the electrical and / or mechanical properties of the coil permeating material can be consistent within the same coil assembly, such as coil assembly 220c, and / or between multiple replicas of the coil assembly, such as coil assembly 220c. Mechanical properties may include adhesion to the windings of the coil, such as coil 220cc, coefficient of thermal expansion, toughness, rigidity, etc. Electrical properties can include dielectric loss, dielectric constant, dielectric breakdown voltage, and conductivity.

[0120] The detailed description of the embodiments above is not an exhaustive description of all embodiments that the inventors intended to fall within the scope of this specification. In fact, those skilled in the art will recognize that certain elements of the above embodiments can be combined or eliminated differently to create other embodiments, and these other embodiments fall within the scope and teachings of this specification. It will also be apparent to those skilled in the art that the embodiments described above can be combined, in whole or in part, to create other embodiments within the scope and teachings of this specification.

[0121] Therefore, although specific embodiments have been described herein for illustrative purposes, various equivalent modifications are possible within the scope of this specification, as will be recognized by those skilled in the art. The teachings provided herein can be applied to other coil spools, tools, systems, and methods for permeating material into coils. Therefore, the scope of the embodiments described above should be determined by the appended claims.

Claims

1. A coil spool (220cb, 1020cb) for winding material into a coil (220cc), the coil spool (220cb, 1020cb) comprising: Bore base (225cb, 1025cb); Bore lip (226cb, 1026cb); as well as Coil grooves (224cb, 1024cb) extend between the base of the spool (225cb, 1025cb) and the lip of the spool (226cb, 1026cb); The coil groove (224cb, 1024cb) includes one or more spool openings (227cb, 1027cb), which are configured to apply a pressure difference to the coil groove (224cb, 1024cb).

2. The coil bobbin (220cb, 1020cb) according to claim 1, wherein, The one or more spool openings (227cb, 1027cb) configured to apply a pressure differential to the coil recesses (224cb, 1024cb) include the one or more spool openings (227cb, 1027cb) configured to allow fluid to enter or exit the coil recesses (224cb, 1024cb).

3. The coil bobbin (220cb, 1020cb) according to claim 2, wherein, The one or more spool openings (227cb, 1027cb) configured to allow the fluid to enter or exit the coil recess (224cb, 1024cb) include the one or more spool openings (227cb, 1027cb) configured to allow permeable material to enter or exit the coil recess (224cb, 1024cb).

4. The coil bobbin (220cb, 1020cb) according to claim 2, wherein, The one or more spool openings (227cb, 1027cb) configured to allow the fluid to enter or exit the coil recess (224cb, 1024cb) include the one or more spool openings (227cb, 1027cb) configured to allow non-permeable materials to enter or exit the coil recess (224cb, 1024cb).

5. The coil bobbin (220cb, 1020cb) according to claim 4, wherein, The non-permeable material includes one of an atmospheric pressure non-permeable material that is displaced into or from the coil grooves (224cb, 1024cb) and a non-atmospheric pressure non-permeable material that is displaced into or from the coil grooves (224cb, 1024cb).

6. The coil bobbin (220cb, 1024cb) according to claim 1, wherein, The coil grooves (224cb, 1024cb) have radii smaller than the radius of the spool base (225cb, 1025cb) and the radius of the spool lip (226cb, 1026cb).

7. The coil spool (220cb) according to claim 1, wherein, The coil grooves (224cb, 1024cb) are at least partially defined by the spool base (225cb, 1025cb) and the spool lip (226cb, 1026cb).

8. The coil bobbin (220cb, 1020cb) according to claim 1, wherein, The one or more spool openings (227cb, 1027cb) include a through hole extending between the surface defining the coil groove (224cb, 1024cb) and the surface defining the inner hole (222cb, 1022cb) of the coil spool (220cb, 1020cb).

9. The coil bobbin (220cb, 1020cb) according to claim 1, wherein, At least one of the one or more spool openings (227cb, 1027cb) includes a groove extending between the spool base (225cb, 1025cb) and the spool lip (226cb, 1026cb).

10. The coil bobbin (220cb, 1020cb) according to claim 1, wherein, The spool base (225cb, 1025cb) also includes at least one coil wire groove (228cb, 1028cb) extending from the outside of the coil spool (220cb, 1020cb) to the coil groove (224cb, 1024cb).

11. A coil transducer (220, 1020) comprising a coil-permeable material in a coil (220cc), the coil transducer (220, 1020) comprising: Coil spools (220cb, 1020cb), said coil spools (220cb, 1020cb) are provided according to any one of claims 1 to 10; A coil (220cc), the coil (220cc) being disposed in a coil groove (224cb, 1024cb) extending between the base of the spool (225cb, 1025cb) and the lip of the spool (226cb, 1026cb); and The coil permeating material (220ci) is disposed between the windings of the coil (220cc) and is substantially free of voids.

12. The coil transducer (220) according to claim 11, wherein, The coil permeation material (220ci) includes at least one of plastic, cement, rubber, epoxy resin, colloidal silica, sodium silicate, silicone resin and aluminum silicate.

13. A vibration device (5), comprising: Vibrating elements (210, 210'); as well as A coil transducer (220) is formed according to any one of claims 11 and 12, and the coil transducer (220) is attached to the vibrating element (210, 210').

14. A method for forming a spool for permeating material into a coil, the method comprising: Form the base of the spool; Form the lip of the spool; A coil groove is formed extending between the base of the spool and the lip of the spool; as well as One or more spool openings are formed in the coil groove to allow a pressure differential to be applied to the coil groove.

15. The method according to claim 14, wherein, Forming one or more spool openings to allow the pressure difference to be applied to the coil recess includes forming one or more spool openings to allow fluid to enter or exit the coil recess.

16. The method according to claim 15, wherein, Forming one or more spool openings to allow the fluid to enter or exit the coil recess includes forming one or more spool openings to allow permeable materials to enter or exit the coil recess.

17. The method according to claim 15, wherein, Forming one or more spool openings to allow the fluid to enter or exit the coil recess includes forming one or more spool openings to allow non-permeable materials to enter or exit the coil recess.

18. The method according to claim 17, wherein, The non-permeable material includes one of an atmospheric pressure non-permeable material that is displaced into or from the coil groove, and a non-atmospheric pressure non-permeable material that is displaced into or from the coil groove.

19. The method of claim 14, wherein, The coil groove has a radius smaller than the radius of the spool base and the radius of the spool lip.

20. The method of claim 14, wherein, The coil groove is at least partially defined by the base of the spool and the lip of the spool.

21. The method according to claim 14, wherein, Forming the one or more spool openings includes a through hole extending between the surface defining the coil recess and the surface defining the inner hole of the coil spool.

22. The method according to claim 14, wherein, Forming at least one of the one or more spool openings includes forming a groove extending between the spool base and the spool lip.

23. The method according to claim 14, wherein, The formation of the spool base also includes forming at least one coil wire groove extending from the outside of the coil spool to the coil groove.

24. A method for forming a coil assembly by permeating material into a coil, the method comprising: Provide a coil spool according to any one of claims 14 to 23; The coil wire is wound around the coil groove of the coil spool; as well as A pressure difference is applied across the one or more spool openings in the coil groove.

25. The method of claim 24, further comprising providing a permeable material to the coil wire wound around the coil groove of the coil spool.

26. The method according to claim 24, wherein, The pressure difference is applied by applying at least one of a negative pressure and a positive pressure to the coil wire wound around the coil groove of the coil spool.

27. The method according to claim 26, wherein, At least one of the negative pressure and the positive pressure applied to the coil wire wound around the coil groove of the coil spool is applied to at least one of the outer and inner portions of the coil wire wound around the coil groove of the coil spool.

28. The method according to claim 26, wherein, At least one of the negative pressure and the positive pressure applied to the coil wire includes pressure applied to one of the permeable material and the non-permeable material of the coil wire wound around the coil groove.

29. The method according to claim 28, wherein, The permeable material includes at least one of plastics, cement, rubber, epoxy resin, colloidal silica, sodium silicate, silicone resin, and aluminum silicate, and the non-permeable material includes air.

30. A tool (1350, 1450, 1550) for permeating material into a coil (220cc), said tool (1350, 1450, 1550) comprising: Material application devices (1352, 1452, 1552) are configured to supply a permeable material to the coil (220cc) under pressure from one or more spool openings (227cb, 1027cb) forming a coil groove (224cb, 1024cb) across the coil spool (220cb, 1020cb).

31. The tool (1350, 1450, 1550) according to claim 30, wherein, The material application device (1352, 1452, 1552) configured to provide the permeable material to the coil (220cc) includes the material application device (1352, 1452, 1552) configured to apply the permeable material to the coil (220cc).

32. The tool (1350, 1450, 1550) according to claim 31, wherein, The pressure that causes the pressure difference across the one or more openings (227cb, 1027cb) of the coil spool (220cb, 1020cb) is greater than atmospheric pressure.

33. The tool (1350, 1450, 1550) according to claim 30, wherein, The material application device (1352, 1452, 1552) configured to provide the permeable material to the coil (220cc) includes the material application device (1352, 1452, 1552) configured to deposit the permeable material onto the coil (220cc).

34. The tool (1350, 1450, 1550) according to claim 33, wherein, The material application device (1352, 1452, 1552) configured to deposit the permeable material onto the coil (220cc) includes the material application device (1352, 1452, 1552) configured to deposit one of the permeable materials under atmospheric pressure and pressure greater than the atmospheric pressure.

35. The tool (1350, 1450, 1550) according to claim 30, wherein, The material application device (1352, 1452, 1552) includes one of a syringe and a nozzle.

36. The tool (1350, 1450, 1550) according to claim 35, wherein, The material application device (1352, 1452, 1552) also includes a sealing surface (1552b) configured to provide a seal.

37. The tool (1350, 1450, 1550) of claim 30 further includes a vacuum application device (1454, 1554) configured to cause the pressure difference across the one or more spool openings (227cb, 1027cb) of the coil groove (224cb, 1024cb).

38. The tool (1350, 1450, 1550) according to claim 37, wherein, The vacuum application device (1454, 1554) includes a sealing surface (1554b) configured to provide a seal.

39. A system (1300, 1400, 1500) for permeating material into a coil (220cc), said system (1300, 1400, 1500) comprising: The tool (1350, 1450, 1550) according to any one of claims 30 to 38 above. A pump (1310) configured to supply a permeable material to the tool (1350, 1450, 1550) under pressure at which one or more spool openings (227cb, 1027cb) of the coil groove (224cb, 1024cb) across the coil spool (220cb, 1020cb) are formed.

40. The system (1300, 1400, 1500) according to claim 39, wherein, The pump (1310) is also configured to receive the permeable material from the tools (1350, 1450, 1550).

41. The system (1300, 1400, 1500) of claim 39 further includes a controller (1330) configured to control at least one of the flow rate and pressure of the permeable material supplied to the tool (1350, 1450, 1550).

42. The system (1300, 1400, 1500) of claim 39 further includes a vacuum pump (1340) configured to provide negative pressure to the tool (1350, 1450, 1550).

Images