# Patent

## Title
Electromagnetic coil assembly for electromagnetic apparatus

## Abstract

An electromagnetic coil assembly for an electromagnetic apparatus has a bobbin, a coil formed of an electrical wire wound a spool of the bobbin, a thermal protection device including a pair of lead wires, a first and a second lead wires, extending from thereof. The first lead wire is connected to one end of the electrical wire through a first connecting member. The second lead wire is connected to one end of a lead wire of an electric circuit through a second connecting member. At least one securing member having a groove-shaped cross-section is secured, e.g., welded securely or fittied pressedly, on a first end surface of the bobbin. The thermal protection device, the first connecting member, and the second connecting member are disposed on the first end surface of the bobbin and are covered by the securing member.

## Background
This application is a division of U.S. patent application Ser. No. 09/788,368, filed Feb. 21, 2001 now U.S. Pat. No. 6,587,024, which is incorporated herein by reference.


BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electromagnetic coil assembly for use in an electromagnetic apparatus, such as an electromagnetic clutch for use in controlling the transmission of power from an automobile engine to a refrigerant compressor in an automobile air conditioning system. More particularly, it relates to the mounting structure for a thermal protection device, electrical wires, and caulking terminals in the electromagnetic coil assembly.
2. Description of Related Art
Referring to FIGS. 1 and 2, an electromagnetic coil assembly 4, which comprises a bobbin 1 and a coil 3, is known in the art. Bobbin 1 has a toroidal shape having a spool portion, which has an exterior open edge. Coil 3 is formed of electrical wire 2, which is wound around the spool portion. An electromagnetic coil assembly 4, for example, is used in an electromagnetic clutch 6 of a compressor 5 in an automobile air conditioning system, as shown in FIG. 3. Electromagnetic coil assembly 4 may be provided with a thermal protection device 7, e.g., a thermal fuse or a thermal switch, which is sensitive to high temperatures in electromagnetic clutch 6. Thermal protection device 7 isolates a power source, such as an automobile engine, to protect electromagnetic clutch 6 and compressor 5 when high temperatures due to friction are generated between the parts in electromagnetic clutch 6.
Referring again to FIGS. 1 and 2, thermal protection device 7 has a pair of leads, a first lead 7a and a second lead 7b, extending from either end of thermal protection device 7. An end of first lead 7a of thermal protection device 7 is connected to a wire end portion 2a of electrical wire 2 through a first caulking terminal 8. An end of second lead 7b of thermal protection device 7 is connected to a third lead 9, which is connected to the external power source (not shown), through a second caulking terminal 10. Thermal protection device 7, first lead 7a and second lead 7b, wire end portion 2a, and third lead 9 are disposed on a first end surface 1a of bobbin 1. A securing member 11 having a groove-shaped cross-section is fixed securely on first end surface 1a by adhesives. Thermal protection device 7 is fitted into the groove-shaped portion of securing member 11. A pair of projection portions 12a and 12b are formed on first end surface 1a. First lead 7a and second lead 7b are fixeded to projection portions 12a and 12b, respectively. Consequently, thermal protection device 7, as well as first caulking terminal 8 and second caulking terminal 10, is fixed to first end surface 1a of bobbin 1.
As shown in FIG. 1, electromagnetic coil assembly 4 is inserted into a core ring 13 having a groove-shaped cross-section and a toroidal shape in plan view, such that thermal protection device 7 on first end surface 1a is positioned in an open end of core ring 13. Thereafter, a resin 14 is poured into the open end of core ring 13, and electromagnetic coil assembly 4 is fixed within core ring 13.
In electromagnetic coil assembly 4, the retention strength of thermal protection device 7, first caulking terminal 8, and second caulking terminal 10 within core ring 13 is relatively low. Therefore, resin 14 may enter into the spaces between thermal protection device 7, first caulking terminal 8, and second caulking terminal 10 and first end surface 1a of bobbin 1. Consequently, thermal protection device 7, first caulking terminal 8, and second caulking terminal 10 may be pushed upward by resin 14 entering into the spaces between these elements, and as a result, these elements may not be covered by resin 14 and may be exposed outside core ring 13. Thus, when electromagnetic coil assembly 4 disposed in core ring 13 is equipped with the parts, which comprise, for example, electromagnetic clutch 6, defects or damage may occur at thermal protection device 7, first caulking terminal 8, and second caulking terminal 10.
SUMMARY OF THE INVENTION
An object of the present invention is to reduce or eliminate the above-mentioned defects or damage, which may be encountered in known electromagnetic coil assemblies with thermal protection devices and caulking terminals.
In an embodiment of the present invention, an electromagnetic coil assembly for an electromagnetic apparatus comprises a bobbin, a coil, and a thermal protection device. The bobbin comprises a cylindrical tubular spool, and a pair of annular flanges projecting radially from the spool to form an exterior open edge. The coil is formed of an electrical wire. The electrical wire is wound around the spool between the flanges. The thermal protection device has a first and a second lead wires, each extending from one side thereof. The first lead wire is connected to one end of the electrical wire through a first connecting member. The second lead wire is connected to one end of a third lead wire of an electrical circuit through a second connecting member. The thermal protection device, the first lead wire, the second lead wire, the first connecting member, the second connecting member, and one end of the electrical wire, one end of the third lead wire are disposed and fixed on a first end surface of the bobbin. At least one securing member having a groove-shaped cross-section is fixed, e.g., welded securely or fitted pressedly, on the first end surface of the bobbin. The thermal protection device, the first connecting member, and the second connecting member are covered by the securing member.
Other objects, features, and advantages will be apparent to persons of ordinary skill in the art from the following description of the invention with reference to the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more readily understood with reference to the following drawings, in which:
FIG. 1 is a perspective and exploded view of a known electromagnetic coil assembly and core ring;
FIG. 2 is a plan view of a first end surface of a bobbin of the known electromagnetic coil assembly;
FIG. 3 is a longitudinal, cross-sectional view of a known compressor for use in an automotive air-conditioning system, which includes an electromagnetic clutch having an electromagnetic coil assembly;
FIG. 4 is a plan view of a first end surface of a bobbin of an electromagnetic coil assembly, according to a first embodiment of the present invention;
FIGS. 5a-5b are cross-sectional views of securing members depicted in FIG. 4;
FIG. 6 is a cross-sectional view of projection portions depicted in FIG. 4;
FIG. 7 is a plan view of a first end surface of a bobbin of an electromagnetic coil assembly, according to a second embodiment of the present invention;
FIG. 8 is a plan view of a first end surface of a bobbin of an electromagnetic coil assembly, according to a third embodiment of the present invention;
FIGS. 9a-9c are a cross-sectional view of securing members depicted in FIG. 8;
FIG. 10 is a plan view of a first end surface of a bobbin of an electromagnetic coil assembly, according to a fourth embodiment of the present invention;
FIG. 11 is a plan view of a first end surface of a bobbin of an electromagnetic coil assembly, according to a fifth embodiment of the present invention;
FIG. 12 is a cross-sectional view of one deformation embodiment of projection portions depicted in FIG. 4; and
FIG. 13 is a cross-sectional view of one deformation embodiment of projection portions depicted in FIG. 11.



DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 4-6, an electromagnetic coil assembly of a first embodiment of the present invention is shown. An electromagnetic coil assembly 15 comprises a bobbin 16, a coil 18, a thermal protection device 19 (e.g., a thermal fuse or a thermal switch), a first caulking terminal 20, and a second caulking terminal 22. Bobbin 16 has a spool portion, which has an exterior open edge formed by two annular flange on the spool portion. Coil 18 is formed of an electrical wire 17, which is wound around the spool portion of bobbin 16. Thermal protection device 19 has a pair of leads, a first lead 19a and a second lead 19b, each extending from one end of thermal protection device 19. An end of first lead 19a of thermal protection device 19 is connected to a wire end portion 17a of electrical wire 17 through first caulking terminal 20. An end of second lead 19b of thermal protection device 19 is connected to one end portion of a third lead 21, which is connected to the external power source (not shown), through second caulking terminal 22. Thermal protection device 19, first caulking terminal 20, second caulking terminal 22, first lead 19a, second lead 19b, wire end portion 17a, and third lead 21 are disposed on a first end surface 16a of bobbin 16. Another end portion of third lead 21 is wound around the spool portion of bobbin 16.
Securing members 23a, 23b, and 23c having a groove-shaped cross-section are welded securely on first end surface 16a of bobbin 16, as shown in FIG. 5a, or are fitted pressedly on first end surface 16a of bobbin 16, as shown in FIG. 5b. Securing members 23a, 23b, and 23c are fixed on first end surface 16a of bobbin 16, which made of resin. For example, securing members 23a, 23b, and 23c may be fixed to bobbin 16 by high frequency welding. Thermal protection device 19, first caulking terminal 20, and second caulking terminal 22 are covered by securing members 23a, 23b, and 23c, respectively.
Referring again to FIG. 4, projection portions 24a and 24b are disposed on first end surface 16a of bobbin 16. First lead 19a and second lead 19b are secured to projection portions 24a and 24b, respectively. As shown in FIG. 6, projection portions 24a and 24b, each has a hook shape and are molded (e.g., integrally molded) with first end surface 16a of bobbin 16. The thickness of each of projection portions 24a and 24b gradually increases towards its base.
Electromagnetic coil assembly 15 is inserted into a core ring (not shown) having a groove-shaped cross-section and a toroidal shape in plan view, such that thermal protection device 19 on first end surface 16a is positioned in an open end of the core ring. Thereafter, a resin is poured into the open end of the core ring, and electromagnetic coil assembly 15 is fixed within the core ring.
In the electromagnetic coil assembly according to the first embodiment of present invention, thermal protection device 19, first caulking terminal 20, and second caulking terminal 22 are covered by securing members 23a, 23b, and 23c, respectively. Therefore, after electromagnetic coil assembly 15 is fixed within the core ring by using resin, the exposure of thermal protection device 19, first caulking terminal 20, and second caulking terminal 22 from the resin bath may be reduced or effectively eliminated. Tensile force is added to first lead 19a, second lead 19b, wire end portion 17a of electrical wire 17, and third lead 21. Therefore, the reaction force F is transferred from first lead 19a and second lead 19b to projection portions 24a and 24b, which retain first lead 19a and second lead 19b, as shown in FIG. 6. Consequently, projection portions 24a and 24b may be reinforced to have thicknesses gradually increasing towards their bases, so that the deformations of projection portions 24a and 24b by the reaction force F are reduced or eliminated.
Referring to FIG. 7, an electromagnetic coil assembly of a second embodiment of the present invention is shown. In an electromagnetic coil assembly 15′, a thermal protection device 19′, a first caulking terminal 20′, a second caulking terminal 22′, a first lead 19a′ and a second lead 19b′ of thermal protection device 19′, a wire end portion 17a′ of an electrical wire 17′ adjacent to first caulking terminal 20′, and a third lead 21′, which is connected to the external power source (not shown) and is adjacent to second caulking terminal 22′, are covered by securing members 23a′, 23b′, and 23c′, each having groove-shaped cross-sections. The remaining structure of electromagnetic coil assembly 15′ is substantially the same as electromagnetic coil assembly 15. In the electromagnetic coil assembly according to the second embodiment of present invention, thermal protection device 19′, first caulking terminal 20′, second caulking terminal 22′, first lead 19a′ and second lead 19b′ of thermal protection device 19′, wire end portion 17a′ of electrical wire 17′, and third lead 21′ are substantially covered by securing members 23a′, 23b′, and 23c′. Therefore, after electromagnetic coil assembly 15′ is fixed within the core ring by using resin, the exposure of thermal protection device 19′, first caulking terminal 20′, and second caulking terminal 22′ from the resin bath may be reduced or effectively eliminated.
Referring to FIGS. 8, 9a to 9c, an electromagnetic coil assembly of a third embodiment of the present invention is shown. In an electromagnetic coil assembly 15′′, each of securing members 23a′′, 23b′′, and 23c′′ has a hook-shaped cross-section and is welded securely on a first end surface 16a′′ of a bobbin 16′′, as shown in FIG. 9a; is integrally molded with first end surface 16a′′ of bobbin 16′′, as shown in FIG. 9b; or is fitted pressedly on first end surface 16a′′ of bobbin 16′′, as shown in FIG. 9c. A thermal protection device 19′′, a first caulking terminal 20′′, a second caulking terminal 22′′, a first lead 19a′′ and a second lead 19b′′ of thermal protection device 19′′, a wire end portion 17a′′ of an electrical wire 17′′ adjacent to first caulking terminal 20′′, and a third lead 21′′, which is connected to the external power source (not shown) and is adjacent to second caulking terminal 22′′, are substantially covered by securing members 23a′′, 23b′′, and 23c′′. 
The structure of electromagnetic coil assembly 15′′ is substantially the same as electromagnetic coil assembly 15′ except that securing members 23a′′, 23b′′, and 23c′′ are used instead of securing members 23a′, 23b′, and 23c′, and are molded, e.g., integrally molded, with first end surface 16a′′ of bobbin 16′′. In the electromagnetic coil assembly according to the third embodiment of present invention, thermal protection device 19′′, first caulking terminal 20′′, second caulking terminal 22′′, first lead 19a′′ and second lead 19b′′ of thermal protection device 19′′, wire end portion 17a′′ of electrical wire 17′′, and third lead 21′′ are substantially covered by securing members 23a′′, 23b′′, and 23c′′. Therefore, after electromagnetic coil assembly 15′′ is fixed within the core ring by using resin, the exposure of thermal protection device 19′′, first caulking terminal 20′′, and second caulking terminal 22′′ from the resin bath may be reduced or effectively eliminated.
Referring to FIG. 10, an electromagnetic coil assembly of a fourth embodiment of the present invention is shown. In an electromagnetic coil assembly 25, a groove 27 is formed on a first end surface 26aof a bobbin 26. A thermal protection device 28; a first lead 28a and a second lead 28b of thermal protection device 28; a first caulking terminal 29; a wire end portion 30a of an electrical wire 30 adjacent to first caulking terminal 29; a second caulking terminal 31; and a third lead 32, which is connected to the external power source (not shown) and is adjacent to second caulking terminal 31; are disposed in groove 27. The structure of electromagnetic coil assembly 25 is substantially the same as electromagnetic coil assembly 15′′ except that groove 27 is formed instead of securing 23a′′, 23b′′, and 23c′′. 
In the electromagnetic coil assembly according to the fourth embodiment of present invention, thermal protection device 28, first lead 28a, second lead 28b, first caulking terminal 29, wire end portion 30a of electrical wire 30, second caulking terminal 31, and third lead 32 are disposed in groove 27. Therefore, after electromagnetic coil assembly 25 is fixed within the core ring by using resin, the wear resistance between thermal protection device 28, first caulking terminal 29, second caulking terminal 31 and both side walls of groove 27 may prevent thermal protection device 28, first caulking terminal 29, and second caulking terminal 31 from exposuring from the resin bath.
Referring to FIG. 11, an electromagnetic coil assembly of a fifth embodiment of the present invention is shown. In an electromagnetic coil assembly 35, each of projection portions 38a and 38b has a hook shape and is molded, e.g., integrally molded, with a first end surface 36a of a bobbin 36. Projection portion 38a is adjacent to a starting end portion of a first lead 37a of a thermal protection device 37. Projection portion 38b is adjacent to a starting end portion of a second lead 37b of thermal protection device 37. Each of projection portions 41a and 41b has a hook shape and is molded, e.g., integrally molded, with first end surface 36a of bobbin 36. Projection portion 41a retains wire end portion 40a of electrical wire 40 adjacent to first caulking terminal 39. Projection portion 41b retains a third lead 43, which is connected to the external power source (not shown), adjacent to second caulking terminal 42. Wire end portion 40a of electrical wire 40 adjacent to first caulking terminal 39 and first lead 37a of thermal protection device 37 overlap and are secured to projection portions 41a and 38a, which are adjacent to each other, respectively. Third lead 43 adjacent to second caulking terminal 42 and second lead 37b of thermal protection device 37 overlap and are secured to projection portions 41b and 38b, which are adjacent to each other, respectively. The structure of projection portions 38a, 38b, 41a, and 41b is substantially the same as projection portions 24a and 24b in FIG. 6. The structure of electromagnetic coil assembly 35 is substantially the same as the known electromagnetic coil assembly except as described above.
In this embodiment of electromagnetic coil assembly 35, adjacent portions of starting end portions of first lead 37a and second lead 37b of thermal protection device 37 are secured to projection portions 38a and 38b, respectively. The distance between projection portion 38a and projection portion 38b is reduced or minimized. Therefore, the upward force on thermal protection device 37 created by the resin, which is poured into the spaces between projection portions 38a and 38b and first end surface 36a, may be reduced or eliminated. As a result, after electromagnetic coil assembly 35 is fixed within the core ring by using resin, the exposure of thermal protection device 37 from the resin bath may be reduced or eliminated. Further, projection portion 41a, which retains wire end portion 40a of electrical wire 40 adjacent to first caulking terminal 39, and projection portion 41b, which retains lead 43 adjacent to second caulking terminal 42, are disposed on first end surface 36a in addition to projection portions 38a and 38b. Therefore, after electromagnetic coil assembly 35 is fixed within the core ring by using resin, the exposure of thermal protection device 37, first caulking terminal 39, and second caulking terminal 42 from the resin bath may be reduced or effectively eliminated. Further, wire end portion 40a of electrical wire 40 adjacent to first caulking terminal 39 and first lead 37a of thermal protection device 37 overlap and are secured to projection portions 41a and 38a, respectively. Lead 43 adjacent to second caulking terminal 42 and second lead 37b of thermal protection device 37 overlap and are secured to projection portions 41b and 38b, respectively. Consequently, after electromagnetic coil assembly 35 is fixed within the core ring by using resin, the exposure of thermal protection device 37, first caulking terminal 39, and second caulking terminal 42 from the resin bath may be reduced or effectively eliminated.
In the above-described embodiments, the unification of securing members 23a′, 23b′, and 23c′ of FIG. 7 is within the contemplation of the present invention. Referring to FIG. 12, one deformation embodiment of the first embodiment of the present invention, an engagement portion of projection portions 24a and 24b, first lead 19a, and second lead 19b, is shown. It is desirable to gradually reduce the height of the engagement portion above first end surface 16a towards the inner part of the engagement portion. In this embodiment, when first lead 19a and second lead 19b are engaged in projection portions 24a and 24b, first lead 19a and second lead 19b are guided to the inner part of the engagement portion and are pressed on first end surface 16a. As a result, after electromagnetic coil assembly 15 is fixed within the core ring by using resin, the exposure of thermal protection devices 19, first caulking terminal 20, and second caulking terminal 22 from the resin bath may be reduced or effectively eliminated.
Further, the unification of securing members 23a′′, 23b′′, and 23c′′ of FIG. 8 is also within the contemplation of the present invention. Referring to FIG. 13, one deformation embodiment of the fifth embodiment of the present invention, an engagement portion of projection portions 38a, 38b, 41a, and 41b, and first lead 37a and second lead 37b, wire end portion 40a of electrical wire 40, and third lead 43, is shown. It is desirable to gradually reduce the height of the engagement portion above first end surface 36a towards the inner part of the engagement portion. In this embodiment, when first lead 37a and second lead 37b, wire end portion 40a of electrical wire 40, and third lead 43 are engaged in projection portions 38a, 38b, 41a, and 41b; and first lead 37a, and second lead 37b; and wire end portion 40a of electrical wire 40; and third lead 43 are guided to the inner part of the engagement portion and are pressed on first end surface 36a. As a result, after electromagnetic coil assembly 35 is fixed within the core ring by using resin, the exposure of thermal protection devices 37, first caulking terminal 39, and second caulking terminal 42 from the resin bath may be reduced or effectively eliminated.
As described above, in the embodiments of the present invention of an electromagnetic coil assembly, securing members having groove-shaped cross-sections, which are welded securely on a first end surface of a bobbin, or which are fitted pressedly on the first end surface of the bobbin, cover a thermal protection device, a first caulking terminal, and a second caulking terminal. Therefore, after the electromagnetic coil assembly is fixed within the core ring by using resin, the exposure of the thermal protection device, the first caulking terminal, and the second caulking terminal from resin bath may be reduced or effectively eliminated.
Although the present invention has been described in connection with preferred embodiments, the invention is not limited thereto. It will be understood by those skilled in the art that variations and modifications may be made within the scope and spirit of this invention, as defined by the following claims.

## Claims

1. An electromagnetic coil assembly for an electromagnetic apparatus comprising:
a bobbin including a cylindrical tubular spool and a pair of annular flanges projecting radially from said spool; 
a coil formed of an electrical wire, said electrical wire wound around said spool between said flanges; 
a thermal protection device having a first and a second lead wires, each extending from one side thereof, said first lead wire connected to one end of said electrical wire through a first connecting member, said second lead wire connected to one end of a third lead wire of an electric circuit through a second connecting member, said thermal protection device, said first lead wire, said second lead wire, said first connecting member, said second connecting member, one end of said electrical wire, one end of said third lead wire disposed on first end surface of said bobbin; and 
a groove formed on said first end surface of said bobbin, such that said thermal protection device, said first connecting member, said second connecting member, said first lead wire, said second lead wire, one end of said electrical wire adjacent to said first connecting member, and one end of said third lead wire adjacent to said second connecting member are disposed in said groove.