Electrical winding and termination interface

Abstract

Methods and devices are provided for supporting a wire having a minimum tolerable bend radius. The device comprises a core portion with a longitudinal axis supporting at least a first portion of the wire and a flange portion attached to the core portion supporting at least a second portion of the wire. The device has at least one hole with a first opening in the first surface defined by a first rim and a second opening in the second surface defined by a second rim. The hole allows the wire to pass through and also supports the wire. The hole is oriented in three dimensions to forestall a bend that may occur in the wire having a bend radius that is less than the minimum tolerable bend radius of the wire.

What is claimed is: 
     
         1 . A device, comprising:
 a ceramic-insulated wire having a coiled portion and an end portion;   a wire support point at which the end portion of the ceramic-insulated wire terminates;   a flange fixedly having first and second opposing sides, the first side facing the coiled portion of the ceramic-insulated wire; and   first and second holes formed in the flange and each extending from the first side to the second opposing side thereof;   wherein the end portion of the ceramic-insulated wire extends from the coiled portion through the first hole, to the second side of the flange, through the second hole, and to the first side of the flange before terminating at the wire support point.   
     
     
         2 . The device of  claim 1  further comprising a spindle fixedly coupled to the flange and around which the coiled portion of the ceramic-insulated wire is wound. 
     
     
         3 . The device of  claim 2  further comprising a core fixedly coupled to the flange opposite the spindle, the end portion of the ceramic-insulated wire extending at partially around the core when transitioning from exiting the first hole to entering the second hole. 
     
     
         4 . The device of  claim 3  wherein the core has a longitudinal axis, and wherein first and second holes are each angled with respect to the longitudinal axis. 
     
     
         5 . The device of  claim 1  further comprising:
 a third hole formed through the flange; and 
 a component including a second wire to which the end portion of the ceramic-insulated wire is electrically connected at the wire support point. 
 
     
     
         6 . The device of  claim 5  wherein the second wire extends from the second side of the flange, through the third hole, and to the first side of the flange and terminates adjacent the wire support point. 
     
     
         7 . The device of  claim 1  wherein first and second holes each comprise rims sculpted to have a radius of curvature greater than a minimum tolerable bend radius of the ceramic-insulated wire. 
     
     
         8 . A device, comprising:
 a wire support point;   a ceramic-insulated wire having a coiled portion and an end portion, the end portion of the ceramic-insulated wire extending from the coiled portion to the wire support point;   a core having a longitudinal axis and around which the end portion of the ceramic-insulated wire is at least partially wrapped; and   a flange fixedly coupled to the core opposite the coiled portion of the ceramic insulated wire, the end portion of the ceramic insulated wire extending through the flange at least once when extending from coiled portion of the ceramic-insulated wire to the wire support point.   
     
     
         9 . The device of  claim 8  wherein the end portion of the ceramic-insulated wire extends through the flange at least twice when extending from coiled portion of the ceramic-insulated wire to the wire support point. 
     
     
         10 . The device of  claim 8  further comprising a first hole formed in the flange and angled with respect to the longitudinal axis, the end portion of the ceramic-insulated wire extending through the first hole when extending from the coiled portion of the ceramic-insulated wire to the wire support point. 
     
     
         11 . The device of  claim 10  further comprising a second hole formed in the flange, the second hole angled with respect to the longitudinal axis and with respect to the first hole, the end portion of the ceramic-insulated wire further extending through the second hole when extending from the coiled portion of the ceramic-insulated wire to the wire support point. 
     
     
         12 . The device of  claim 8  further comprising a spindle around which the coiled portion of the ceramic-insulated wire is disposed, the spindle fixedly coupled to the core portion at a first end thereof. 
     
     
         13 . The device of  claim 12  wherein:
 the flange has first and second opposing sides, the second side is located between the first side and the first end of the core portion to which the spindle is fixedly coupled; 
 the flange includes first and second holes therein; and 
 the ceramic-insulated wire extends through the first hole from the second surface to the first surface, is wrapped around the core portion one or more times, and further extends through the second hole from the first surface to the second surface. 
 
     
     
         14 . A device, comprising:
 a spindle;   a flange fixedly coupled to the spindle;   a first hole formed through the flange and angled with respect to a longitudinal axis of the support device;   a second hole formed through the flange;   a component lead routed through the second hole;   a ceramic-insulated wire, comprising:
 a coiled portion wound around the spindle; and 
 an end portion extending from the coiled portion, through the first hole, and extending to a point of electrical connection with the component lead. 
   
     
     
         15 . The device of  claim 14  wherein the first hole comprises first and second sculpted rims formed in opposing sides of the flange. 
     
     
         16 . The device of  claim 14  wherein the component lead comprises a wire. 
     
     
         17 . The device of  claim 14  further comprising a third hole formed through the flange and angled with respect to a longitudinal axis of the support device, the end portion of the ceramic-insulated wire extending from the coiled portion, through the first hole, through the third hole, and terminating at the point of electrical connection with the component lead. 
     
     
         18 . The device of  claim 14  further comprising a core fixedly coupled to the flange, the end portion of the ceramic-insulated wire wrapped at least once around the core. 
     
     
         19 . The device of  claim 18  wherein the flange comprises:
 a first side facing the coiled portion of the ceramic-insulated wire; and 
 a second opposing side facing the core. 
 
     
     
         20 . The device of  claim 19  further comprising a component including the component lead, the component lead extending from the component, entering the second hole at the second side of flange, and exiting the second hole at the first side of the flange before terminating at the point of electrical connection with the end portion of the ceramic-insulated wire.