Patent ID: 6170148
Filing Date: 2001-01-09
Classification: G01B,G01D,G01H,G01K,H01F,Y10T

Abstract:
A method for making a transducer, the steps including: providing an air core coil having a hollow interior defining a center void and first and second leads extending from said coil;connecting said leads of said coil to conductors of a leading portion of a cable;forming an alignment plug including molding a front end flush with a front face of said air core coil without covering said front face of said air core coil, molding a back end over a length of said leading portion of said cable and, molding a medial portion contacting and contouring to an entire back face of said air core coil and integrally formed with and interposed between said front end and said back end of said alignment plug for capturing said air core coil and said leading portion of said cable, said medial portion of said alignment plug including an integrally formed outer peripheral wall contacting and contouring to an exterior surface of said air core coil and extending substantially parallel thereto, and molding a center post integrally formed with said medial portion of said alignment plus and extending a distance into said center void of said air core coil, said outer peripheral wall, said medial portion and said center post defining an annular recess integrally formed in said alignment plug and contacting and contouring to said exterior surface, said back face and a first portion of said center void of said air core coil;leaving a second portion of said center void of said air core coil unfilled with said alignment plug;aligning said alignment plug within an injection mold cavity with an axially slidable support being received within said unfilled portion of said center void of said air core coil;subsequently retracing said axially slidable support andinjection molding a uniform uninterrupted front wall immediately forward said air core coil and a body over an entirety of said alignment plug and a portion of said cable defining a mass ensconcing said air core coil, said alignment plug and said leading portion of said cable.