Method and apparatus for manufacturing toroidal cores

Abstract

A method of winding a toroidal core through a bobbin aperture, including the steps of: providing a fixture having a cavity defined by first and second continuous arcuate walls, the first continuous arcuate wall having contiguous first and second surface portions of differing curvature; placing a bobbin having an aperture therethrough into the fixture such that the bobbin aperture opens into the cavity; feeding a ribbon of strip stock material having a leading edge and first and second sides into the fixture; feeding the leading edge of the ribbon through the bobbin aperture; sliding the ribbon along the second arcuate wall of the cavity; directing the leading edge of the ribbon toward and into sliding contact with the first surface portion of the first arcuate wall of the cavity; sliding the leading edge of the ribbon from the first surface portion of the first arcuate wall of the cavity to the second surface portion of the first arcuate wall of the cavity; and feeding the leading edge of the ribbon again through the bobbin aperture and placing the first side of the ribbon adjacent the second side of the ribbon within the cavity, whereby a coil comprised of a plurality of ribbon layers is formed through the bobbin aperture.