Background of the Invention [2]. Prior United States Patents of magnetic core winders, which include but are not limited to toroidal winders, include U. S. Patents 5,331, 729; 4,379, 527; 4, S72, 618 ; 6, 557,793 ; 4, 288, 041 ; and 5,875, 988. In general, the prior art, as shown in FIGS. 1 through 3, illustrate the principle of winding magnet wire on a magnetic core (hereinafter"core") to create an inductor. The prior art uses a supply ring 10 and winding ring 20 with pullout or open/close type ring openings 12 and 22 to enable a core 30 to be arranged with the rings 10 and 20 passing through the center hole of the core 30. In the prior art the openings 12 and 22 are opened manually and the core 30 is passed through the openings so that each ring passes through the center hole 32 of the core, with the central axis 34 of the magnetic core 30 at right-angles to the central axis 25 of the rings.

[3] The supply ring 10 has a U-shaped groove 14 around its circumference. In order to enable wire 40 to be wound into the groove 14, the end of the wire 40 is manually attached to the supply ring 10. The winding ring 20 has substantially the same diameter as the supply ring 10, with which it is aligned concentrically. The winding ring 20 has a wire guide 24 via which wire 40 is drawn from the supply ring 10 and a guide roller 26 to guide the wire 40.

[4] In an actual winding operation, the core 30 is first manually inserted onto the rings 10 and 20 via the openings 12 and 22 and positioned as shown in FIG. 2. The end of the wire 40 is then attached to the supply ring 10 and the supply ring 10 is rotated around its central axis to wind the required amount of wire 40 into the groove 14. After cutting the trailing end of the wire 40, the cut end is passed through the wire guide 24 and around the guide roller 26, and is drawn radially outwards from between the rings and affixed to a retainer means or the like (not shown) provided on the periphery of the core 30.

[5] As shown by FIG. 3, when the core 30 is being wound, a drive (not shown) is used to rotate the supply ring 10 and winding ring 20 in the opposite direction from that used to load the wire 40 onto the supply ring 10, and the wire 40 is drawn from the supply ring 10 through the wire guide 24 and guide roller 26 on the winding ring 20 and attached to the core 30. In this state, the wire wound around the supply ring 10 is spirally wound a required number of turns around the core 30, and the wire left over on the supply ring 10 is manually removed. Finally, the core wound with the wire, that is, the inductor, is removed.

[6] The ideal single layer inductor would have a low temperature rise, high inductance, and small size. Moreover, it has been found that by increasing the wire size, total number of turns, and decreasing the core size, these more desirable properties can be achieved. Moreover, since rectangular wire has a smaller width then round wire (for a given gauge), rectangular wire may be used to increase the number of turns on a core and thus increase the inductance. As such, US Patents directed to manufacturing or forming rectangular wire from round wire are found in the art, for example, US Patent 6, 553,650.

[7] The winding of rectangular wire on the edge however is extremely difficult. Referring now to FIG 4, when the wire 40 forms around the corners 34 of the core 30, the wire has a tendency to twist and lie diagonally. If the wire 40 is guided tightly on either side of the corner, the twisting can be prevented but in winding a core there is insufficient space to guide the wire as it wraps around the internal wall 36 of the core 30. In some instances, the rectangular wire is formed and the core has a piece cut therefrom which permits the wire to be slipped onto the core.

However, when a piece is removed the magnetic properties may decrease and the inductance of the core may be reduced.

[8] It is thus an object of the present invention to overcome the problems associated with the prior art while maintaining an inductor with a low temperature rise, high inductance, and a small size.

Summary of the Invention [9] In view of the above drawbacks of the prior art, an object of the present invention is to provide an inductor with lower temperature rise, higher inductance, smaller size, or less EMI noise when compared to an inductor made in accordance with the prior art.

[10] To achieve the above object, the present invention provides a core to be wound with a wire. A portion of the wire is first wrapped around an outer edge of a form tool positioned in front of the core. The outer edge of the form tool is shaped similarly to the inside diameter of the core. Once the portion of the wire is formed around the form tool, the portion of the wire will be preformed with a shape that matches the inside shape of the core. Thus, providing a tight fit around such the inside diameter of the core. The form tool can be retracted such that the wire can be pulled through the core wherein the preformed portion of the wire aligns with the inside shape of the core. This process can be repeated until the core is wound to form an inductor. This process is also preferred when the wire is rectangular. In an embodiment where the wire is round, the wire once formed around the form tool is flattened or pinched. The pinched portion of the wire once wound around the core will allow a more efficient winding around the core and thereby provide an inductor with a lower temperature rise, higher inductance, or smaller size.

The process can be achieved with either an automatic winding apparatus or using a manually hook winding method.

[11] After a first layer of wire is wound around the magnetic core, multiple layers can be wound using the same process to form transformers. When switching to a second layer, the form tool should be replaced with a second form tool that has an outside shape that matches the inside shape of the first layer of wire, such that the second layer of wire winds closely around the first layer.

[12] The process of providing an inductor with a formed wire as described above may be manufactured with rectangular wire or round wire and by manual hook winding process or on an automatic winder.

Brief Description of the Drawings [13] A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein: [14] FIG 1 is a disassembled perspective view of a prior art shuttle; [15] FIG 2 is a perspective view of a prior art shuttle; [16] FIG 3 shows the direction of rotation of the shuttle and the run of the wire during winding using a prior art winder; [17] FIG 4 illustrates the supplying of the wire during each rotation of the shuttle of a prior art winder; [18] FIG 5 shows the main parts of a core automatic winding apparatus in accordance with the present invention; [19] FIG 6 is the core automatic winding apparatus of FIG 5 rotated 180° ; [20] FIG 7 shows the core automatic winding apparatus of FIG 5 with the flattening tool pinching the wire; [21] FIG 8 is the core automatic winding apparatus of FIG 6 with the forming tool retracted; [22] FIG 9a is a cross sectional view of the core and forming tool illustrating the wire wrapped around the forming tool; [23] FIG 9b is a cross sectional view of the core of FIG 9a with the forming tool retracted; [24] FIG 10 is a cross sectional view of the core with the wire pinched and with the forming tool retracted; [25] FIG I 1 a is a side view of an inductor; [26] FIG 11 b is a cross sectional view of the inductor of FIG 11 a ; [27] FIG lie is a side view of a transformer that includes two different gauge wires, each wound around approximately half of a magnetic core; [28] FIG 12 shows the main parts of a hook winding apparatus in accordance with one embodiment of the present invention ; [29] FIG 13 is a perspective view of the hook winding apparatus from FIG 12 illustrating the flattening tool pinching the wire; [30] FIG 14 is a perspective view of the hook winding apparatus from FIG 12 illustrating the flattening tool and the form tool being retracted; [31] FIG is a perspective view of the hook winding apparatus from FIG 12 illustrating the wire being pulled tight around the core; [32] FIG 16a is a perspective view of a hook winding apparatus with a guide tool positioned about the form tool to prevent a rectangular wire from warping while the wire is spirally wound around a core; and [33] FIG 16b is a perspective view of the hook winding apparatus with the guide tool partially removed from the form tool table, done for illustration purposed only.

Detailed Description of the Embodiments [34] While the invention is susceptible to embodiments in many different forms, there are shown in the drawings and will be described herein, in detail, the preferred embodiments of the present invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit or scope of the invention and/or claims of the embodiments illustrated.

[35] Referring now to FIG 5 there is illustrated a magnetic core automatic winding apparatus 100 (winder) according to the present invention. In this embodiment, the winder 100 includes a supply ring and a winding ring, referred to herein as a shuttle 102. A shuttle rotation mechanism (not shown) drives the shuttle 102, while a core rotation mechanism and support 106 rotates a magnetic core 200. The apparatus 100 further includes a control unit 105 for controlling the rotation mechanisms 112 and 106.

[36] The magnetic core 200 (referred to herein as"core") is generally, but not limited to electrical oval or other noncircular core shapes and may be as shown toroidal in shape.

Moreover, the magnetic core 200 may or may not have a solid ring, such that the ring may include liquid or hybrid liquid/solid interior.

[37] The shuttle 102 includes a U-shaped winding groove (not shown) for holding a wire 150 and a shuttle guide roller 108 that guides the wire 150 out of the shuttle 102. The shuttle rotation mechanism is used to independently rotate the shuttle such that the wire 150 can be pulled out of the shuttle 102. The shuttle rotation mechanism includes a drive roller 112 that engages and drives the shuttle 102. In addition, a plurality of drive support rollers 114 may be included to help guide or rotate the shuttle during the winding of the core 200.

[38] The apparatus 100 may also include a brake mechanism 104, also controlled by the control unit 105, for placing tension on the wire 150. The brake mechanism 104 includes a first brake piece 104a and a second brake piece 104b secured about the shuttle 102. The second brake piece 104b is suspended from the first brake piece 104a by pins 110. When the brake mechanism is activated by the control unit 105, tension is applied to the wire 150, such that the wire IS0 is maintained in a taut position.

[39] The core rotation mechanism 106 includes two drive rollers 116 located at a specified point along the shuttle 102, with one drive roller above the shuttle 102 and the other below. The two drive rollers 116 engage the core 200 such that when operating the core 200 may rotate about its axis.

[40] Referring also to FIGS 6 through 8, the automatic winder 100 further includes a form table 130 positioned and aligned with the core 200. The form table 130 includes a form tool 132 that is horizontally moveable in relation to the form table 130, The form tool 132 may thus be moved a specified distance D (FIG 9a) from the outside wall 206 of the core 200. The specified distance is defined as being substantially equal to the length of the outside wall 206 of the core 200. The form tool 132 is also retractable within the form table 130, which as explained in greater detail below, is done when the wire 150 is wrapped around the core 200.

[41] Referring also to FIG 9a, the form tool 132 includes an outside profile 135 that is substantially the same as an inside profile 205 defined by the core 200. As used throughout this invention the outside profile 135 of the form tool 132 may be defined as just the outside wall 136 or may be defined to include the sidewalls 138. Furthermore the inside profile 205 defined by the core 200 may include just the inside wall 207 or may be defined to include the sidewalls 209 such that any corners formed between the inside wall 207 and the sidewalls 209 are defined by the definition of the inside profile of the core 200. Thus, the inside profile of the core 200 may include straight, rounded, or slightly arced corners. Irregardless of the exact shape, it is an important aspect of the invention that the form tool have a matching profile such that the wire 150 is wound tight against the inside profile 205 of the core 200. Moreover, as used in this invention, the core may include an outside profile 206 that may include any portion not covered by the inside profile 205.

[42] If the wire 150 is rectangular, the wire 150 is wrapped around the form tool 132 and then the form tool 132 is retracted (shown in FIG 9b as being removed for clarity, and as seen in FIG 8 the form tool 132 is recessed down into the form table 130). The wire 150 thus includes a preformed portion 154 (identified between numerals 152) that substantially aligns with the inside profile 205 defined by the core 200. As such, the core 200 will be wrapped with a more tightly fitted wire providing for an ideal inductor.

[43] Continuing to refer to FIG 7, if the wire 150 is round, the automatic winder 100 is also equipped with a flattening tool 160. The flattening tool used, may be, pneumatic presses, hydraulic presses, toggle presses, flywheel type presses, or hammers. The flattening tool 160 includes a notched section 162 that accommodates for the form tool 132. When the flattening tool 160 is pressed down onto the wire 150 (FIG 7) the preformed portion 154 of the wire 150 is pinched or substantially flattened. Once flattened the flattening tool 160 is lifted away from the forming table 130 and the forming tool 132 is retracted (FIG 8) to permit the preformed and flattened wire 150 to be pulled and wrapped around the core 200.

[44] Illustrated in FIG 10, the preformed portion 154 of the wire 150 is flattened and is shown as having a larger thickness than the non-flattened portion, illustrated generally as flattened preformed wire 156. It is appreciated by those skilled in the art that the portion of the flattened wire 150 may be less or more than what is illustrated without departing from the teachings herein. Moreover, the substantial change in thickness of the wire 150 is done only to illustrate that a change in thickness has taken place. The change in thickness may be less dramatic such as that formed by a tapering region between the flattened and non-flattened portions of the wire 150.

[45] The core 200 is then rotated and the process is repeated until the desired turns are made spirally wrapping to form a inductor 210, illustrated in FIGS 11a and llb. By flattening or pinching the portion of wire, the width is reduced which allows more turns per layer of the wire around the core. This creates an inductor 210. that can have a lower temperature rise, higher inductance, and be smaller in size as compared to an inductor made in accordance to the prior art. As illustrated, the wire 150 is pinched preferably at an angle such that there is a tapering region 158 from the unpinched wire to the pinched wire.

[46] It is appreciated from the present invention that after the core is spirally wound, additional layers of wire may be added. The teachings of the invention provide that a form tool have an outside profile that matches the inside profile of the layer of wire that the additional layer is placed thereon. In. addition, different gauge wires may be used on the same core, as illustrated in FIG 11C. A first gauge wire 150a is spirally wound around a first portion 220a of a core 200 and a second gauge wire 150b is spirally wound around a second portion 220b of the same core 200.

[47] The angle at which the wire is pinched may be different to achieve various results.

However, the angle which permits the most amount of turns for a given wire will depend upon the inside of the core when the outside turns are touching each other. Mathematically, the angle is determined by the following el [48] angle = sin-'Wire Diameter Wire Diameter + Core Outer Diameter [49] When the present invention is employed the following characteristics were determined : (1) increase inductance-using the present invention, more turns of the same wire size can be added to the same core, this will increase the inductance of the inductor when all other things remain equal; (2) lower temperature rise-the present invention allows a larger diameter wire to fit into the internal diameter of the core without changing the size of the core, a larger diameter wire reduces the copper losses and will therefore reduce the temperature rise; (3) decrease size- the present invention allows more turns of the same wire size to be wound around a smaller core and therefore decreases the size and weight, as such a smaller design will be able to have the same inductance and temperature rise; and (4) decrease noise-the present invention also decreases the electro magnetic interference ("EMI") or noise normally produced by an inductor; this is due to the gap between the start and finish of the wound wire, as the larger gap decreases EMI. <BR> <BR> <P>[50] The core 200 may also be wound manually in a process known as"hook winding. "The present invention includes winding a core by a hook winding process and apparatus with the additional feature of forming corners in the wire that correspond to the inside corners of the core and/or flattens or pinches a portion of the wire that wraps around the side wall, inside corners and inside wall of the core. It also being appreciated that the pinched portion may be more or less then what is illustrated herein.

[5 1]-Referring now to FIGS 12 through 15, a hook winding apparatus 300 is illustrated and a method for winding a core using said apparatus will be disclosed. A wire 150 (typically round for this example) is provided with a lead portion 151 secured to a post 302. The post 302 may be provided on the core rotation mechanism and support 106. The wire 150 is wrapped around the form tool 132 and placed in a hook 312 that is extended to an initial position from a hook support 310. The hook 312 is retracted to pull the wire around the form tool 132 to form a preformed portion 154 (such as shown in FIG 9b) in the wire 150. The wire is then pinched prior to winding around the core. A flattening or pinching tool 160 is pressed down onto the wire 150 (FIG 13). As mentioned above the wire may be pinched about the preformed portion 154 that corresponds to the inside profile of the core 200. The wire may include a tapering region between the pinched portion and unpinched portion. The.. flattening tool 160 and the form tool 132 is retracted (FIG 14). The wire 150 is pulled tight around the core 200 (FIG 15) such that the pinched preformed portion aligns with the inside profile of the core 200. The core 200 is rotated, the form tool 132 is extended, and the hook 312 is extended or placed in the initial position. The process is repeated until the core is spirally wound with the wire 150 with the formed corners.

[52] Referring now to FIG 16a and FIG 16b in another embodiment, a hook winding apparatus 400 is used with a rectangular wire 402 with a lead portion 404 secured to a post 306.

The post 306 may be provided on a core rotation mechanism and support 408. The wire 402 is wrapped around a form tool 410 with an outside profile as previously discussed. The wire 402 is also placed in a hook 412 that is extended to an initial position from a hook support 414. The hook 412 is retracted to pull the wire around the form tool 410 to form a preformed portion 416 in the wire 402. A guide tool 420 is used to guide the rectangular wire around the form tool 410 without having the wire twist or wrap around when the preformed portion is being formed. The form tool 410 is retracted (not shown) and the wire 402 is pulled tight around the core 425 such that the preformed portion 416 aligns with the inside profile of the core 425. The core 425 is \ rotated and form tool 410 is extended. The hook 412 is also extended or placed in the initial position. The process is repeated until the core is spirally wound with the wire 402. While FIG 16b illustrated the guide tool 420 being moved or retracted, it is only moved for purposes of illustrating other components of the apparatus 400. the guide tool 420 may be fixed in positioned such that the wire 402 slides between the guide tool 420 and the form table 430.

[53] Comparison between an inductor made in accordance with the present invention being both formed and pinched (hereinafter"Pinched Wire") to a round-wire inductor is shown in the following tables: [54] Table No. 1 represents the"Pinched Wire"calculations for a core such as a Magnetics Inc. part number 77083-A7 core. Using the present invention an inductance of 245mH and a temperature rise of 38. 5°C was calculated. All calculations in the table are based on a single layer winding and a minimum start to finish wire spacing of 0.319". This spacing and single layer winding are necessary to maintain acceptable EMI levels.

[55] Table No. 1 Pinched Wire Core Size 0. 95" ID x 1. 57" OD x 0. 57" High Finished Coil Size 0. 77" ID x 1. 75" OD x 0. 75" High Wire Size 14 1/2 AWG (Pinched dimension 0. 038" x 0.090") Turns 55 Inductance 245 mH DC Resistance 25 mQ Temperature Rise with 12ADC 38. 5°C Spacing between Start & Finish 0.319" [56] Table No. 2 shows the maximum round wire that can be wound on the same core (Magnetics Inc. p/n 77083-A7) such that the number of turns are equal to that which was achieved in the Pinched Wire example above. The calculations show that for an equivalent inductance the wire size must be reduced to 17 ! 4 AWG. The reduction in wire size yields a 104% increase in DC Resistance and an 80% increase in temperature rise (as temperature rise °C = [Total power dissipation mW/Available surface area cmz) o. s33 [57] Table No. 2 Maximum Round Wire Utilizing Same Core Core Size 0. 95" ID x 1. 57" OD x 0. 57"High Finished Coil Size 0. 86"ID x 1. 66" OD x 0. 66" High Wire Size 17 V2AWG Turns 55 Inductance 245 mH DC Resistance 51 mQ Temperature Rise with 12ADC 69. 4°C Spacing between Start & Finish 0. 376" Table No. 3 shows an 11.4% increase in OD necessary to maintain the same Height, Inductance, and temperature rise as the"Pinched Wire"technique, [59] Smallest Core/Coil Size for Equivalent Inductance, Temperature Rise, and Terminal Spacing Using Round Wire [60] Table No. 3 Core Size 0.95 ID x 1. 85"OD x 0. 57" High Finished Coil Size 0.84 ID x 1. 95" OD x 0. 68"High Wire Size 16 AWG Turns 46 Inductance 245 mH DC Resistance 36 mQ Temperature Rise with 12ADC 42. 4°C Spacing between Start & Finish 0.368" [61] From the foregoing and as mentioned above, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the novel concept of the invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.