Method of making a rotary electric machine especially suitable for use as a starter for automotive vehicle engines

Claim 1

A method of making a rotary electric machine suitable for use as a starter for automotive vehicle engines which comprises a generally cylindrical yoke, a plurality of pole cores each fixed to said cylindrical yoke through a central projecting portion and a plurality of field coils each wound in a space defined by the cylindrical yole, the pole core and the central projecting portion, said method comprising the steps of: forming an electrically insulating coating on the inner surface of said generally cylindrical yoke; forming an electrically insulating coating on the surfaces of said pole cores opposite to said inner surface of said cylindrical yoke; forming a conductor of a plurality of randomly bundled, electrically insulated wires, said wires forming a plurality of parallel conductive paths through said conductor and rendering the cross-sectional shape of said conductor readily deformable; winding said conductor formed of said plurality of randomly bundled, electrically insulated wires directly on one of said central projecting portions and within said space, and thereafter continuously winding said conductor directly on another central projecting portion in sequence in order to form said field coils, each of said field coils having plural numbers of winding turns; and applying an electrical insulator to fill gaps between said field coils and said cylindrical yoke and said pole cores.

Claim 2

A method of making a rotary electric machine suitable for use as a starter for automotive vehicle engines which comprises a generally cylindrical yoke, a plurality of pole cores each fixed to said cylindrical yoke through a central projecting portion and a plurality of field coils each wound in a space defined by the cylindrical yole, the pole core and the central projecting portion, said method comprising the steps of: forming an electrically insulating coating on the inner surface of said generally cylindrical yoke; forming an electrically insulating coating on the surfaces of said pole cores opposite to said inner surface of said cylindrical yoke; forming a conductor of a plurality of randomly bundled, electrically insulated wires, said wires forming a plurality of parallel conductive paths through said conductor and rendering the cross-sectional shape of said conductor readily deformable; winding said conductor formed of said plurality of randomly bundled, electrically insulated wires directly on one of said central projecting portions and within said space, and thereafter continuously winding said conductor directly on another central projecting portion in sequence in order to form said field coils, each of said field coils having plural numbers of winding turns; and applying an electrical insulator to fill gaps between said field coils and said cylindrical yoke and said pole cores.

Claim 6

A method of making a rotary electric machine suitable for use as a starter for automotive vehicle engines which comprises a generally cylindrical yoke, a plurality of pole cores each fixed to said cylindrical yoke through a central projecting portion and a plurality of field coils each wound in a space defined by the cylindrical yoke, the pole core and the central projecting portion, said method comprising the steps of: forming an electrically insulating coating on the inner surface of said generally cylindrical yoke; forming an electrically insulating coating on the surfaces of said pole cores opposite to said inner surface of said cylindrical yoke; forming a wire assembly of a plurality of randomly bundled, electrically insulated wires, said wires forming a plurality of parallel conductive paths through said wire assembly and rendering the cross-sectional shape of said wire assembly readily deformable; winding said wire assembly formed of said plurality of randomly bundled, electrically insulated wires directly on one of said central projecting portions and within said space, and thereafter continuously winding said wire assembly directly on another central projecting portion in sequence in order to form said field coils, each of said field coils having plural numbers of winding turns; and applying an electrical insulator to fill gaps between said field coils and said cylindrical yoke and said pole cores.

Claim 7

A method of making a rotary electric machine suitable for use as a starter for automotive vehicle engines which comprises a generally cylindrical yoke, a plurality of pole cores each fixed to said cylindrical yoke through a central projecting portion and a plurality of field coils each wound in a space defined by the cylindrical yoke, the pole core and the central projecting portion, said method comprising the steps of: forming an electrically insulating coating on the inner surface of said generally cylindrical yoke; forming an electrically insulating coating on the surfaces of said pole cores opposite to said inner surface of said cylindrical yoke; forming a wire assembly of a plurality of randomly bundled, electrically insulated wires, said wires forming a plurality of parallel conductive paths through said wire assembly and rendering the cross-sectional shape of said wire assembly readily deformable; winding said wire assembly formed of said plurality of randomly bundled, electrically insulated wires directly on one of said central projecting portions and within said space, and thereafter continuously winding said wire assembly directly on another central projecting portion in sequence in order to form said field coils, each of said field coils having plural numbers of winding turns; and applying an electrical insulator to fill gaps between said field coils and said cylindrical yoke and said pole cores.

Claim 8

A method of making a rotary electric machine suitable for use as a starter for automotive vehicle engines which comprises a generally cylindrical yoke, a plurality of pole cores each fixed to said cylindrical yoke through a central projecting portion and a plurality of field coils each wound in a space defined by the cylindrical yoke, the pole core and the central projecting portion, said method comprising the steps of: forming an electrically insulating coating on the inner surface of said generally cylindrical yoke; forming an electrically insulating coating on the surfaces of said pole cores opposite to said inner surface of said cylindrical yoke; simultaneously winding a plurality of randomly bundled, electrically insulated wires directly on one of said central projecting portions and within said space, and thereafter continuously winding simultaneously said plurality of randomly bundled electrically insulated wires directly on another central projecting portion in sequence in order to form said field coils, each of said field coils having a plural number of winding turns; and applying an electrical insulator to fill gaps between said field coils and said cylindrical yoke and said pole cores.

Claim 9

A method of making a rotary electric machine suitable for use as a starter for automotive vehicle engines which comprises a generally cylindrical yoke, a plurality of pole cores each fixed to said cylindrical yoke through a central projecting portion and a plurality of field coils each wound in a space defined by the cylindrical yoke, the pole core and the central projecting portion, said method comprising the steps of: forming an electrically insulating coating on the inner surface of said generally cylindrical yoke; forming an electrically insulating coating on the surfaces of said pole cores opposite to said inner surface of said cylindrical yoke; simultaneously winding a plurality of randomly bundled, electrically insulated wires directly on one of said central projecting portions and within said space, and thereafter continuously winding simultaneously said plurality of randomly bundled electrically insulated wires directly on another central projecting portion in sequence in order to form said field coils, each of said field coils having a plural number of winding turns; and applying an electrical insulator to fill gaps between said field coils and said cylindrical yoke and said pole cores.