Coil assembly and method of making the same

Claim 2

A coil assembly comprising an elongated coil form having a body of molded insulating material, a first coil molded in place oN said coil form having a plurality of turns with a selected spacing between adjacent turns, a second coil having a single turn or less molded in place on said coil form in coaxial relation with and spaced between a pair of adjacent turns of said first coil, said second coil including a pair of integral connector leads at opposite ends of said single turn extending outwardly of said coil form between spaced adjacent turns of said first coil, and insulating support means integrally molded on said coil form body around said connector leads for securing said second coil in spaced apart relation between said adjacent turns of said first coil, said connector leads projecting outwardly beyond said support means for making external electrical connections.

Claim 3

The coil assembly of claim 1 including a third coil having a single turn or less mounted on said coil form in coaxial relation with and spaced between a pair of adjacent turns of said first coil, said third coil including a pair of integral connector leads at opposite ends of said single turn extending outwardly of said coil form between spaced adjacent turns of said first coil, and connector means remote from said coil form for interconnecting adjacent connector leads from said second and third coils whereby said coils form a tapped common winding of said inductance.

Claim 4

The coil assembly of claim 1 in combination with a printed circuit board having circuit conductors thereon connected with said connector leads for supporting said inductance on said circuit board, said support means having end surfaces in spacing contact against said circuit board.

Claim 5

The coil assembly of claim 2 wherein said connector means comprises a printed circuit board having circuit conductors thereon, said coil connector leads extending generally in a common direction toward said circuit board and connected to said conductors thereon for supporting said inductance on said circuit board, said support means including end surfaces for contact against said circuit board to maintain a selected spacing between said board and said coil form body.

Claim 6

The coil assembly of claim 1 wherein said connector leads of said second coil are parallel and said single turn or less and said connector leads lie in a common plane angularly intersecting the longitudinal axis of said coil form.

Claim 7

A coil assembly comprising an elongated coil form having a body of molded insulating material, a first coil molded in place on said form including a plurality of turns with a selected pitch distance between adjacent turns, a second coil having a single loop and molded in place on said coil form spaced between a pair of adjacent turns of said first coil, said second coil having a pair of end leads extending outwardly of said form from between adjacent turns of said first coil, insulating support means integrally molded on said form body around said leads for holding said second coil in said spaced apart relation between adjacent turns of said first coil, a third coil having a single loop and molded in place on said coil form spaced between a pair of adjacent turns of said first coil and including a pair of end leads extending outwardly of said form from between adjacent turns of said first coil, insulating support means integrally molded on said form body around the end leads of said third coil for holding said third coil in spaced apart relation between adjacent turns of said first coil, said end leads of said second and third coils extending, respectively, outwardly of said support means for making external electrical connections.

Claim 8

A coil assembly comprising an elongated coil form having a body of molded insulating material, a first coil molded in place on said form including a plurality of turns with a selected pitch distance between adjacent turns, a second coil having a single loop and molded in place on said coil form spaced between a pair of adjacent turns of said first coil, said second coil having a pair of end leads extending outwardly of said form from between adjacent turns of said first coil, insulating support means integrally molded on said form body around said leads for holding said second coil in said spaced apart relation between adjacent turns of said first coil, a third coil having a single loop and molded in place on said coil form spaced between a pair of adjacent turns of said first coil and including a pair of end leads extending outwardly of said form from between adjacent turns of said first coil, insulating support means integrally molded on said form body around the end leads of said third coil for holding said third coil in spaced apart relation between adjacent turns of said first coil, said end leads of said second and third coils extending, respectively, outwardly of said support means for making external electrical connections.

Claim 11

The method of claim 7 wherein coaxial alignment between the turns of said first and second coils is obtained by moving a second mold forming member into a closed position forming a cavity for said coil form.

Claim 12

The method of claim 8 wherein said turns are compressed radially inwardly during coaxial alignment by moving said second mold forming member into said closed position.