Bobbin-Wound Coil Layout to Eliminate Flange Bulges

The patent inverts the conventional winding pattern by having the coil begin and end at radially inner locations near the cylindrical body rather than at the radially outer edge. The coil then winds outward and back inward, crossing over itself to terminate at the terminal connector. This inversion eliminates the outwardly projecting bulge that plagued conventional designs, simplifying manufacturing and packaging while maintaining proper electrical connection.

The patent implements self-service through the coil's own geometry and routing. The coil beginning and end portions are routed through the terminal connector in a manner that creates inherent mechanical tension and anchoring. The crossing pattern and terminal connector geometry work together to automatically tension and secure the coil ends without requiring external tensioning devices, maintaining structural simplicity while ensuring reliability.

The patent extracts or eliminates the harmful feature of recesses that trap fluids and debris. By redesigning the flange exterior surface to be substantially flat without recesses, the design removes the pockets where contamination could accumulate. The weight reduction objective is achieved through alternative means, such as optimizing the overall flange thickness or using appropriate materials, rather than creating recesses that would compromise cleanliness.

The patent employs asymmetry to prevent rotation. The bobbin or field shell is designed with asymmetric features such as flats, keys, or offset mounting positions that create a unique angular orientation. This asymmetric geometry prevents the bobbin-coil assembly from rotating relative to the field shell during operation, as rotation would misalign the asymmetric features. The mounting structure remains relatively simple while effectively eliminating rotational instability.