US3763551A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of manufacturing a tubular printed circuit armature
Assignee: International Business Machines Corp
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Filing: 1972-06-12
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Granted: 1973-10-09
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Expires: 1992-06-12
Abstract
Abstract Tubular high torque - low inertia printed circuit armatures are manufactured from two flexible circuit cards. Each card is comprised of a layer of conductive metal laminated to a layer of insulation. The layer of insulation is patterned to expose a pair of spaced parallel bands of metal, on the insulation side of each card. These spaced bands form the circuit interconnecting tabs of the metal winding conductors which extend into the spaced bands. The abutting surfaces of the two cards are coated with an adhesive which will bond the cards together under a heat and pressure environment. The cards are loosely rolled about a low or zero temperature coefficient mandrel, with the interconnecting tabs of one card in registry with the interconnecting tabs of the other card, and with the cards axially overlapping one another at the sides which form the axial seam of the tubular armature. The diameter of the mandrel accurately establishes the inner diameter of the finished armature. The mandrel and encircling cards are placed in an inflatable oven. This oven is formed by a rubber sleeve or tube which carries an integral heater and a temperature sensor. The oven is pressurized to thereby force the two cards down onto the mandrel. The heater is energized and a servocontrolled temperature is maintained for a given time period. The resulting tube is removed from the mandrel, and the tabs are electrically connected to form the armature winding.
Inventors
- 👤 C Herron
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 05:25
CPC Classifications
H; H02; H02K; H02K3/00; H02K3/04; H02K3/26; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49009; Y10T29/49012
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
245 words
The method of manufacturing a tubular printed circuit armature for an electrical machine, comprising the steps of: preparing at least two laminated cards having a flexible layer of electrically conductive metal bonded to a patterned flexible layer of electrical insulation, the pattern in said layer of insulation providing spaced surfaces of exposed metal layer on the insulation side of the cards, coating at least one side of one card with a layer of thermal activated adhesive, such that said spaced surfaces of said metal layer remain uncoated, placing said cards into a pneumatic-electric oven having an open-end, tubular shaped flexible wall/heater, with said cards loosely surrounding a tubular shaped manufacturing mandrel having a substantially zero temperature coefficient of expansion, such that (a) said one side of said one card is adjacent the other card, (b) said spaced surfaces of said metal layer in each of said cards are in alignment, and (c) said cards overlap to form a double card thickness at the central portion and a single card thickness at each end portion, the end portions then overlapping to form an axial seam in the tube which is thereby formed about said mandrel, pressurizing said oven to force said cards mechanically together and radially inward onto the underlying surface of said mandrel, energizing said oven to activate said adhesive, subsequently de-energizing and depressurizing said oven, and thereafter removing said mandrel from said oven and mechanically forcing said cards off one end of said mandrel.
Claim 2
Independent Claim
245 words
The method of manufacturing a tubular printed circuit armature for an electrical machine, comprising the steps of: preparing at least two laminated cards having a flexible layer of electrically conductive metal bonded to a patterned flexible layer of electrical insulation, the pattern in said layer of insulation providing spaced surfaces of exposed metal layer on the insulation side of the cards, coating at least one side of one card with a layer of thermal activated adhesive, such that said spaced surfaces of said metal layer remain uncoated, placing said cards into a pneumatic-electric oven having an open-end, tubular shaped flexible wall/heater, with said cards loosely surrounding a tubular shaped manufacturing mandrel having a substantially zero temperature coefficient of expansion, such that (a) said one side of said one card is adjacent the other card, (b) said spaced surfaces of said metal layer in each of said cards are in alignment, and (c) said cards overlap to form a double card thickness at the central portion and a single card thickness at each end portion, the end portions then overlapping to form an axial seam in the tube which is thereby formed about said mandrel, pressurizing said oven to force said cards mechanically together and radially inward onto the underlying surface of said mandrel, energizing said oven to activate said adhesive, subsequently de-energizing and depressurizing said oven, and thereafter removing said mandrel from said oven and mechanically forcing said cards off one end of said mandrel.
Claim 3
Dependent Claim
42 words
The method as defined in claim 1 wherein said mandrel includes an axial opening, and including the step of admitting a heating and/or cooling medium to the inner portion of said mandrel substantially coincident with energization and/or subsequent deenergization of said oven.
Claim 4
Dependent Claim
37 words
The method as defined in claim 1 wherein said wall/heater includes an integral electrical heater about the circumference of said cards and an integral temperature sensor, and including the step of servo-controlling the temperature of said wall/heater.
Claim 5
Dependent Claim
27 words
The method as defined in claim 3 including the step of placing an axially split metal sleeve between the outer one of said cards and said wall/heater.
Claim 6
Dependent Claim
54 words
The method as defined in claim 4 wherein said metal sleeve is identical in shape to the outer of said two cards, and wherein said step of placing said metal sleeve over said outer card includes the step of aligning the axial seam of said sleeve with the axial seam of said outeR card.
Claim 7
Dependent Claim
83 words
The method as defined in claim 1 wherein, prior to the step of coating with said adhesive, each of said cards are processed to produce a plurality of individual armature conductors in the metal layer, each of said individual conductors terminating in said spaced surfaces of said metal layer, and wherein said cards are placed on said mandrel in a manner such that the terminating portion of a conductor in one card overlaps the terminating portion of a conductor of the other card.
Claim 8
Dependent Claim
33 words
The method as defined in claim 6 wherein said flexible wall/heater is constructed and arranged such that the step of pressurizing said chamber does not force said terminating portions of said conductors together.
Claim 9
Dependent Claim
34 words
The method as defined in claim 6 wherein, after said mandrel is removed from said shell and said cards are forced off said mandrel, said overlapping terminating portions of said conductors are electrically interconnected.
Claim 10
Dependent Claim
50 words
The method as defined in claim 8 wherein said cards include selvage material at the end of each card adjacent said spaced surfaces of said metal layer, and including the step of forming manufacturing holes in said selvage material, and aligning said manufacturing holes with indicia carried by said mandrel.
Claim 11
Dependent Claim
41 words
The method as defined in claim 9 wherein said wall/heater includes an integral electrical heater disposed about the total circumference of said cards, and also includes an integral temperature sensor, and including the step of servo-controlling the temperature of said wall/heater.
Claim 12
Dependent Claim
60 words
The method as defined in claim 10 including the step of placing a metal sleeve, having the same shape as the outer card, between said outer card and said wall/heater to ensure uniform distribution of pressure and heat to said cards, and the step of aligning the axial seam of said sleeve with the axial seam of said outer card.
Claim 13
Dependent Claim
43 words
The method as defined in claim 11 wherein said mandrel includes an axial opening, and including the step of admitting a heating and/or a cooling medium to the inner portion of said mandrel substantially coincident with energization and/or subsequent de-energization of said oven.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1976-10-08 | 1977-04-09 | 1977-10-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1980-10-08 | 1981-04-09 | 1981-10-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1984-10-08 | 1985-04-09 | 1985-10-09 | $7700.00 | Window Closed / Lapsed |