Magnetic coil manufacturing
One aspect is for a method of manufacturing a magnetic coil for a magnetic actuator. A coil carrier is provided which comprises a tubular section and a collar which adjoins the tubular section, wherein the coil carrier is arranged for accommodating a coil winding. A die comprising a defined inner contour is provided which is adapted to the coil carrier. The coil carrier is inserted into the die, wherein the collar of the coil carrier rests on a seating surface of the die. The collar is punched with a punch, wherein a flange contour is formed at the collar the outline of which is defined by an inner contour of the die. The coil carrier is also at least sectionally potted or overmolded with a filler material, wherein the flange contour provides a barrier for the filler material. The disclosure further relates to a corresponding magnetic coil.
1. A method of manufacturing a magnetic coil for a magnetic actuator, the method comprising the following steps:
providing a coil carrier comprising a tubular section and a collar, wherein the coil carrier is arranged for accommodating a coil winding,
providing a magnet pot comprising a defined inner contour which is adapted to the coil carrier,
inserting the coil carrier in the magnet pot, wherein the collar of the coil carrier rests on a seating surface of the magnet pot,
punching the collar with a punch that cooperates with the magnet pot, wherein, at the collar, a flange contour is formed such that an outline is defined by the inner contour of the magnet pot,
arranging the coil carrier in the magnet pot, wherein the flange contour is arranged in a fashion recessed with respect to the seating surface, and
at least sectionally filling the magnet pot with a filler material, wherein the flange contour provides a barrier for the filler material.
2. The method according to claim 1 , wherein the filler material is a thermoplastic material, and wherein the filler material is equivalent to material from which the coil carrier is made.
3. The method according to claim 1 , further comprising forming an undercut contour at the collar of the coil carrier, wherein the step of at least sectionally filling the magnet pot involves a penetration of the filler material into the undercut contour.
4. A method of manufacturing a magnetic coil for a magnetic actuator, the method comprising the following steps:
providing a coil carrier comprising a tubular section and a collar which adjoins the tubular section, wherein the coil carrier is arranged for accommodating a coil winding,
providing a die comprising a defined inner contour which is adapted to the coil carrier,
inserting the coil carrier in the die, wherein the collar of the coil carrier rests on a seating surface of the die,
punching the collar with a punch, wherein, at the collar, a flange contour is formed such that an outline is defined by the inner contour of the die, and
at least sectionally filling the coil carrier with a filler material, wherein the flange contour provides a barrier for the filler material.
5. The method according to claim 4 , wherein the die is arranged as a magnet pot and comprises a circumferential section which surrounds the inner contour and forms the seating surface, and wherein the coil carrier remains in the magnet pot after the punching of the collar.
6. The method according to claim 4 , wherein, after the punching of the collar, the flange contour is arranged in a fashion recessed with respect to the seating surface.
7. The method according to claim 4 , wherein the step of at least sectionally filling the coil carrier involves feeding the filler material from a feeding side which is facing away from a collar side of the coil carrier defined by the collar, and wherein the barrier provided by the flange contour provides a sealing for the filler material.
8. The method according to claim 4 , wherein the step of at least sectionally filling the coil carrier involves an overmolding, with a thermoplastic material, of the coil carrier that is provided with the coil winding.
9. The method according to claim 8 , wherein the thermoplastic material for overmolding the coil carrier is equivalent to a material from which the coil carrier is made.
10. The method according to claim 4 , further comprising providing a hold-down device for the at least sectionally filling of the coil carrier, wherein the hold-down device contacts the collar, and wherein the hold-down device is adapted to the inner contour of the die and comprises a defined offset with respect to the inner contour of the die.
11. The method according to claim 4 , further comprising forming a defined cutting edge at the die.
12. The method according to claim 4 , further comprising providing a counter holder for accommodating the coil carrier in the die, wherein the counter holder defines a position of the coil carrier in the die.
13. The method according to claim 4 , further comprising forming an undercut contour at the coil carrier.
14. The method according to claim 4 , wherein an undercut contour involves at least one undercut opening at the collar of the coil carrier, and wherein the step of at least sectionally the coil carrier involves a penetration of the filler material into the undercut contour.
15. The method according to claim 4 , further comprising providing a position securing section at the inner contour of the die, wherein the formed flange contour provides for a rotation orientation in such a way that the coil carrier is arranged to be coupled with the die in a fashion fixed against rotation.
16. The method according to claim 4 , wherein the coil carrier further comprises an opposite flange arranged at an end of the tubular section facing away from the collar, and wherein the coil winding is arranged between the collar and the opposite flange.