Abstract: Axisymmetric solid of revolution derivable from section at FIG. 5 is generally toroidal with electric current(s) in windings preferably flowing circumferentially along major circle(s) during power coupling device operation. Current(s) in windings, current(s) in half-shields, and the volume of space swept out by shield airgap(s) emerge from plane of paper perpendicularly at FIG. 5, but as these emerge therefrom, they curve to follow toroidal major circle(s). Core regions preferably shunt and align magnetic flux such that magnetic field lines escape therefrom primarily only in region(s) of core airgap(s) and such that magnetic flux loops lie in planes of toroidal minor circle(s). Half-shield(s) preferably have electrically conductive material(s) distributed therein as is sufficient to substantially cancel magnetic flux lines impinging thereon before effects of such impinging magnetic flux lines would reach shield airgap(s) and/or outer surface(s) of half-shields.

Abstract: The present invention provides an axial air-gap rotary electric machine with which it is possible to achieve downsizing and increased output as well as an improvement in the support strength of a molded resin and housing and a reduction in the manufacturing cost of the housing. Provided is an axial air-gap rotary electric machine having: a stator in which a plurality of core members, which have at least an iron core and a coil, are arranged in a circular shape centered around a rotating shaft and curved around the inner peripheral surface of a housing; and a rotor that faces an end surface of the iron core with a prescribed air gap therebetween in the radial direction of the rotating shaft. Therein, the housing has, in the surface facing the stator, a hole that communicates with the outside, and the stator has a resin molded portion formed by filling a resin into at least the surface of the core members facing the inner peripheral surface of the housing, and into the hole, and molding integrally.

Abstract: A transformer device includes: a transformer that includes a magnetic body core and a winding; a case that houses the transformer; an external terminal that is provided in the case; a relay section that is provided in the case and to which an end portion of the winding of the transformer is connected; and a conducting wire of which one end is wound around the external terminal and bonded thereto, and another end is connected to the relay section.

Abstract: A magnetic device fabrication method includes the step of using molds to respectively process a first substrate and a second substrate into respective predetermined shapes, the step of forming conductors in shaped protruding blocks of the first substrate and conducting contacts in the second substrate, the step of attaching one or more magnetic cores to the first plate member to couple one or more positioning slots to the protruding blocks of the first plate member respectively and the step of bonding one or multiple magnetic cores between the first and second substrate to provide a continuous winding type induction coil effect, saving much manufacturing labor and time.

Abstract: A rotor of a motor capable of improving durability of the motor by increasing a bonding force between a ring magnet and a resin. The rotor includes a ring magnet having an insertion hole passing through the center thereof, a shaft inserted into the insertion hole, and a resin that is disposed between the insertion hole and the shaft and fixes the ring magnet and the shaft. The resin extends to upper and lower surfaces of the ring magnet so as to cover at least parts of the upper and lower surfaces of the ring magnet.

Abstract: A stainless steel motor with high weather resistance and high sealing performance comprises a cylindrical housing (11) made of a stainless steel material. A front end cover (12) is arranged at one end of the cylindrical housing, and a rear end cover (13) is arranged at the other end of the cylindrical housing. A rotary shaft hole (12a) is provided in the front end cover. A rotary shaft sealing sleeve (12b) is arranged in the rotary shaft hole, and a rotor shaft (12) is sleeved in the rotary shaft sealing sleeve (12b). A first drainage structure is arranged on the front end cover, and a second drainage structure is arranged on the rear end cover. A first wire penetrating hole (11a) and a second wire penetrating hole (11b) are provided in the cylindrical housing.

Abstract: A high frequency inductor filter cooling apparatus, method of manufacture, and method of use thereof is described. In one embodiment, an inductor is potted in an epoxy-silica mixture to facilitate thermal transfer from the inductor. The inductor is optionally used with a capacitor to filter/invert/convert power. The inductor optionally comprises a distributed gap core and/or a powdered core material. In one example, a minimum carrier frequency used with the filter is above that usable by a traditional wound iron-steel inductor, such as greater than seven hundred or ten thousand Hertz at fifty or more amperes. Optionally, the inductor is used in an inverter/converter apparatus in conjunction with a notched low-pass filter, a low pass filter combined with a notch filter and a high frequency roll off filter, and/or one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.

Abstract: An apparatus includes a substrate layer formed from a pottant material that extends longitudinally in an unwound state. Cores are spaced longitudinally along the substrate layer and joined to the substrate at a first surface. The apparatus further includes pottant segments joined to the cores at a second surface opposite the first surface.

Abstract: We describe a method of manufacturing a housing for the stator of an axial flux permanent magnet machine, the machine having a stator comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: fabricating a radial wall for said stator housing to be located in said gap between said rotor and said stator by: placing a resin membrane into a mold of an injection molding machine; injection molding a set of reinforcing features onto said membrane using a thermoplastic polymer bondable when molten with said resin; and manufacturing said housing using said radial wall.

Abstract: Disclosed is a motor, the motor according to exemplary embodiments of the present disclosure including an insulator body coupled to a stator core wound with a plurality of coils applied with powers of mutually different polarities to prevent the coil and the stator coil from being short-circuited, a terminal housing coupling unit integrally formed with the insulator body to be coupled to a terminal housing supplying an outside power by being circumferentially protruded, and a coil guide unit formed at the terminal housing coupling unit to prevent coils connected to a terminal of each polarity installed at the terminal housing from being short-circuited.

Abstract: A method of molding a resin casing covering a stator of a motor may include preparing first and second molds; disposing the stator in the first mold; combining the molds; pouring a resin into the cavity; curing the resin; separating the molds; and taking the stator and resin casing from the mold. The stator may include a core, an insulator, and a coil. The core may include a core back surrounding and teeth that extend inward from the core back. The insulator may include wall portions inside the coil. The wall portions may be provided around the teeth and extend toward one side in an axial direction. One of the molds may include cylindrical surfaces contacting inner end faces of the teeth. The first mold may include wall supporting surfaces contacting or facing the inner surfaces of the wall portions. The wall supporting surfaces may be outside the cylindrical surfaces.

Abstract: Electrical circuit assemblies flood coated with polymeric flood coat compositions as described or exemplified herein are provided. The flood coat composition is characterized as having a sufficient gel time and thixotropic index as to substantially cover or encapsulate the electrical circuit assembly as a fixed mass upon cure such that the thickness of the polymeric coating on surfaces horizontal to the assembly is from 20 mils to 75 mils, and the thickness on surfaces vertical to the assembly is from 4 mils to 20 mils. Such flood coated assemblies and devices containing same are advantageous over conventional potting materials or conformal coatings because they require less material thereby reducing weight and cost, and they are able to withstand extreme environmental stresses such as from temperature and/or vibrations.

Abstract: A method of molding a resin casing covering a stator of a motor may include preparing first and second molds; disposing the stator in the first mold; combining the molds; pouring a resin into the cavity; curing the resin; separating the molds; and taking the stator and resin casing from the mold. The stator may include a core, an insulator, and a coil. The core may include a core back surrounding and teeth that extend inward from the core back. The insulator may include wall portions inside the coil. The wall portions may be provided around the teeth and extend toward one side in an axial direction. One of the molds may include cylindrical surfaces contacting inner end faces of the teeth. The first mold may include wall supporting surfaces contacting or facing the inner surfaces of the wall portions. The wall supporting surfaces may be outside the cylindrical surfaces.

Abstract: A rotor of a motor capable of improving durability of the motor by increasing a bonding force between a ring magnet and a resin. The rotor includes a ring magnet having an insertion hole passing through the center thereof, a shaft inserted into the insertion hole, and a resin that is disposed between the insertion hole and the shaft and fixes the ring magnet and the shaft. The resin extends to upper and lower surfaces of the ring magnet so as to cover at least parts of the upper and lower surfaces of the ring magnet.

Abstract: A high frequency inductor filter cooling apparatus and method of use thereof is described. In one embodiment, an inductor is potted in an epoxy-silica mixture to facilitate thermal transfer from the inductor. The inductor is optionally used to filter/invert/convert power. The inductor comprises a distributed gap core and/or a powdered core material. In one example, the minimum carrier frequency is above that usable by an iron-steel inductor, such as greater than ten kiloHertz at fifty or more amperes. Optionally, the inductor is used in an inverter/converter apparatus, where output power has a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies, in conjunction with a notched low-pass filter, a low pass filter combined with a notch filter and a high frequency roll off filter, and/or one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.

Abstract: A method of manufacturing an armature for an electric motor, includes: placing a commutator and a lamination stack on an armature shaft, winding magnet wire in slots in the lamination stacks to form coils, attaching ends of the magnet wire to the commutator, and molding plastic around the magnet wire and around the shaft of the armature at ends of the lamination stack. A spinning inertia of the armature is adjusted by adjusting at least one of a mass of the plastic molded and a distribution of the plastic molded. Alternatively and/or additionally, at least one of a resonant frequency and critical speed of the armature is adjusted by adjusting at least one of a geometry of the plastic molded, the physical properties of the plastic and the mechanical properties of the plastic.

Abstract: A method of manufacturing a planar board substrate for receiving a magnetic core. The method includes providing a cover layer having a layer side and providing a base layer having first and second sides. The base layer includes a material hole that extends completely through the base layer between the first and second sides. The method also includes coupling the cover and base layers to each other along the first side and the layer side. The cover layer extends over at least a portion of the material hole. The method also includes providing a dielectric member within the material hole, wherein a core-holding channel exists between the dielectric member and the base layer. The core-holding channel extends circumferentially around the dielectric member and is configured to have a magnetic core therein.

Abstract: A printed circuit board package structure includes a substrate having a first surface and a second surface, a ring-shaped magnetic element, an adhesive layer, conductive portions and conductive channels. The first and second surfaces respectively have first and second metal portions. A ring-shaped concave portion is formed on a position not covered by the first metal portions of the first surface. The ring-shaped magnetic element is placed in the ring-shaped concave portion. The adhesive layer covers the first metal portions and the ring-shaped magnetic element. The conductive portions are formed on the adhesive layer. The conductive channels penetrate the conductive portions, the adhesive layer, and the substrate, and are respectively located in an inner wall and outside an outer wall of the ring-shaped concave portion. Each of the conductive channels includes a conductive film electrically connects to the aligned conductive portion and second metal portion.

Abstract: An ignition coil for an internal combustion engine is equipped with an assembly of a connector casing and a coil body. The coil body includes a primary winding wound around a primary spool. The connector casing has terminals each of which is equipped with a conductor fastener. The conductor fastener has a slit in which one of ends of the primary winding is fit to make an electric connection between the terminal and the primary winding. The primary spool has conductor guides and a backup support to establish alignment of each of the ends of the primary winding with one of the conductor fasteners and also to facilitate insertion of each of the ends of the primary winding into one of the conductor fasteners when the coil body is fitted into the connector casing, thereby ensuring the stability of electric connection between the primary winding and the terminal.

Abstract: An apparatus for fabricating a semiconductor package may include a mold and a molding plate. The mold may define a mold cavity with the mold being configured to receive a circuit board in the mold cavity, and the circuit board may include a semiconductor chip mounted thereon. A molding plate may be moveable in the mold cavity with the molding plate being configured to adjust a volume of the mold cavity. Related methods are also discussed.

Abstract: A method for forming an armature for an electric motor includes: securing a lamination stack having slots therein on an armature shaft, securing a commutator on one end of the armature shaft, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, the magnet wires having armature lead wires that extend from the slots to the commutator; and molding plastic over the magnet wires to encase at least the armature lead wires in plastic. Alternatively and/or additionally, plastic is molded over the magnet wires to retain them in the slots and to support the armature lead wires and prevent them from vibrating when the armature rotates during operation.

Abstract: There is disclosed a transformer, comprising a triangular wound core; a low voltage LV winding; and at least one high voltage HV foil disc winding and a method for manufacturing a transformer coil, comprising providing a high voltage HV inner mold assembly; and winding at least one HV foil disc winding on the HV inner mold assembly. There is also disclosed a mold for manufacturing a transformer coil, comprising side gears respectively arranged at top and bottom positions of a triangular wound core; a high voltage HV inner mold assembly connected to the side gears; and a HV outer mold assembly connected to the side gears, wherein the HV outer mold assembly has a top opening across a length thereof.

Abstract: [Problem] Provided is an injection-molded reactor which has a further reduced loss when the reactor is in operation. [Solution Means] The injection-molded reactor is configured by injection-molding a core using a compound for a core so that a coil obtained by winding a electric wire is embedded in the core without leaving any space therein, the compound being a compound obtained by adding a low-melting-point resin B that has a melting point of 150° C. or lower to a base resin A that is a highly heat-resistant resin with a melting point of 150° C.

Abstract: There is provided a transformer including: a bobbin; a primary coil member mounted in the bobbin; and a secondary coil member formed integrally with the bobbin.

Abstract: A method of sealing coil leads during encapsulation by placing a lead of a coil in a tube, such that there remains a gap between the lead and the tube; placing the coil in a mold such that the gap remains open to an environment surrounding the mold; and injecting encapsulation material into the closed mold in a liquid state under pressure, thereby causing the material to flow through the gap toward the environment. Injecting encapsulation material into the mold may be done at a rate, temperature, and/or environmental temperature to cause the material to solidify before passing through the gap into the environment. In any case, there is no need to seal the mold to the leads. Each lead of the coil may be placed into an individual tube and/or the tubes may be is formed within a single sleeve.

Abstract: An electromagnetic solenoid is provided with a bobbin having a generally cylindrical body and a pair of radially outwardly extending end flanges each disposed at opposite ends of the generally cylindrical body. The pair of end flanges each have an inner face facing one another and an outer face facing away from one another. The inner and outer faces of the pair of end flanges have a plurality of grooves formed in a surface thereof. The grooves provide for enhanced retention of an over-mold that seals a coil within the bobbin assembly.

Abstract: The method of manufacturing a molded article including a component insert-molded in a molding material mixed with solid powder includes an injecting step of injecting the molding material and the solid powder into a molding die, an agitating step of agitating the molding material and the solid powder within the molding die to disperse the solid powder in the molding material, and an embedding step of pressing and embedding the component into an agitated mixture of the molding material and the solid powder.

Abstract: The exemplary embodiment provides a method of manufacturing a molded article including a component insert-molded in a molding material mixed with solid powder. The method includes an injecting step of injecting the molding material and the solid powder into a molding die, an agitating step of agitating the molding material and the solid powder within the molding die to disperse the solid powder in the molding material, and an embedding step of pressing and embedding the component into the agitated mixture of the molding material and the solid powder while vibrating at least one of the component and the molding die.

Abstract: [Problem] To provide a method of manufacture for an encased coil body, which is capable of easily manufacturing an encased coil body which is configured so as to be encased in a state where a coil is enclosed within an electrically insulating resin and is also capable of favorably preventing the coil from positional misalignment or deformation at the time of the manufacture.

Abstract: A detecting sensor is disclosed having a magnet, a plurality of magnetic field detecting sensor elements, and a housing. The magnetic field detecting sensor elements have a plurality of adjacent, overlapped bodies and a plurality of terminals projecting from the bodies in a same direction. The housing is disposed over the magnet and plurality of sensor elements, and has first and second sensor holding members. The first sensor holding member is positioned on a first side of the housing and abutted against a surface of the body on a first side of the plurality of sensor elements. The second sensor holding member is positioned on a second side of the housing and abutted across a portion of a surface of the body of the sensor element on a second side of the plurality of sensor elements.

Abstract: Disclosed herein is a method of manufacturing a coil, including: preparing a mold having vertically movable fixing pins disposed therein and slidable left and right sidewalls; seating a magnetic plate on an inner bottom of the mold; loading the coil on the magnetic plate so that lead parts of the coil are disposed between the fixing pins and the sidewalls of the mold; sliding the left and right sidewalls of the mold into the mold to closely adhere the lead parts of the coil to the fixing pins; filling a magnetic slurry in the mold and primarily pressing the magnetic slurry; and lowering the fixing pins to perform secondary pressing, in order to prevent deformation or position deviation of the coil at the time of molding the coil.

Abstract: An inductor that has the following: an inductor core comprising a plurality of core members arranged in a ring with gaps therebetween; primary insert-molded resin parts comprising a thermoplastic resin covering the outside surface of the inductor core, excluding the surfaces of the core members that face each other; coils disposed around the aforementioned gaps and the primary insert-molded resin parts on the inductor core; and secondary insert-molded resin parts comprising a thermoplastic resin insert-molded around the coils to affix said coils to the inductor core. This allows high-cycle manufacturing of inductors without a thermosetting-resin potting step in a vacuum furnace or a heat curing treatment in a heating furnace.

Abstract: An apparatus for fabricating a semiconductor package may include a mold and a molding plate. The mold may define a mold cavity with the mold being configured to receive a circuit board in the mold cavity, and the circuit board may include a semiconductor chip mounted thereon. A molding plate may be moveable in the mold cavity with the molding plate being configured to adjust a volume of the mold cavity. Related methods are also discussed.

Abstract: There is provided a transformer including: a bobbin; a primary coil member mounted in the bobbin; and a secondary coil member formed integrally with the bobbin.

Abstract: A method for producing a magnetic field sensor for use in drive train of a motor vehicle includes encapsulating an electrical assembly and an end of a connecting cable via injection molding and integrally extruding a fastening tab. After a first injection step in which the electrical assembly and the connecting cable are encapsulated in a core-type first molded part, a second injection molding step in implemented in which a fastening tab is integrally formed via injection molding on the core-type insertion part in a specifiable longitudinal and/or angular position. The core-like insertion part is held in the injection mold in a longitudinally displaceable and/or rotatable manner.

Abstract: In one embodiment, a stimulation lead comprises: a lead body of insulative material surrounding a plurality of conductors; a plurality of electrodes; and a plurality of terminals, the plurality of terminals electrically coupled to the plurality of electrodes through the plurality of conductors; wherein each conductor of the plurality of conductors is helically wound about an axis within the lead body in at least an outer portion and an inner portion relative to the axis, the outer portion comprises a first winding pitch and the inner portion comprises a second winding pitch, the second winding pitch is less than the first winding pitch, the inner portion of each respective conductor being disposed interior to the outer portions of other conductors of the plurality of conductors; wherein an impedance of each conductor of the plurality of conductors substantially reduces MRI-induced current when the stimulation lead is present in an MRI system.

Abstract: A method of manufacturing a power module on a substrate. In one embodiment, the method includes providing power conversion circuitry including providing a magnetic device having a magnetic core and at least one switch on the substrate. The method also includes placing a shielding structure with a baffle over the magnetic core to create a chamber thereabout. The method also includes depositing an encapsulant about the power conversion circuitry. The shielding structure limits the encapsulant entering the chamber and the baffle directs the encapsulant away from the magnetic core thereby limiting an amount of the encapsulant that contacts the magnetic core within the chamber.

Abstract: A method includes coating a conductive wire with a paste comprising a first inorganic dielectric material, an organic binder, and a solvent to form a coated wire, drying the coated wire at a first drying temperature to remove at least a portion of the solvent and form a green wire, winding the green wire around a core to form a green assembly, heat treating the green assembly at a decomposing temperature above the first temperature and below a melting point of the first inorganic dielectric material to decompose the organic binder to form an intermediate assembly, and exposing the intermediate assembly to a densifying temperature that is above the decomposing temperature and substantially equal to or above the melting point of the first inorganic dielectric material to densify the dielectric material on the conductive wire.

Abstract: A reactor 1? includes a coil 2 formed by winding a wire 2w, a magnetic core 3 that is disposed inside and outside of the coil 2 and forms a closed magnetic circuit, and a case 4 that has an opening portion and a bottom surface 40 that opposes the opening portion and that houses an assembly 10 of the coil 2 and the magnetic core 3. At least the opening portion of the case 4 side of the magnetic core 3 is formed of a molded solid body that contains magnetic powder and resin. A surface layer 5, which prevents the magnetic powder from rusting, is provided on a surface of the magnetic core 3 on the opening portion of the case 4 side. The surface layer 5 has a resin portion formed of resin similar to the resin contained in the magnetic core 3. The resin portion is formed so as to be continuous with the resin contained in the magnetic core 3 without an interface formed therebetween.

Abstract: A fluid device includes a housing and a rotor assembly disposed in the housing. The rotor assembly includes a core and a coating. The core has a first surface, an oppositely disposed second surface and an outer peripheral surface that extends between the first and second surfaces. The core defines a bore that extends through the first and second surfaces. The coating coats at least a portion of the core. The coating is a water-swellable plastic material.

Abstract: An article for use in various industries including for manufacturing toys, promotional articles, and decorative articles using plastic includes a body (1), a built-in magnet (3) and a receptacle (2) with side arms (21) embedded in the body (1). The receptacle (2) has a base (23), an opening (25) for introducing the magnet (3), and a closure lid (4) for closing the opening (25).

Abstract: A ferrite powder for producing a ferrite sintered body is provided, the ferrite powder having a median diameter D50 [?m] in a range from 0.1 to 0.8 ?m, a degree of spinel formation in a range from 45 to 90%, and a remanent magnetization Br per unit mass [emu/g] satisfying the following formula after application of the maximum magnetic field of 15 kOe: 0.05?Br?2.0(ln.D50)+6.3. This ferrite powder produces a homogeneous ferrite sintered body having very few cracks by gel casting.

Abstract: The invention relates to a magnetic flux collector for a torque detection device. The collector includes two coaxial magnetic cylinder heads (6, 7), having respectively interlocked teeth (17, 28), overmoulded by means of a plastic material. The two cylinder heads (6, 7) have, at the periphery thereof, notches (18, 19, 23) provided such as to engage with matching grooves (32, 33) which comprise a cylindrical cavity (31) of a mould (30) for overmoulding the cylinder heads with the plastic material. The two cylinder heads (6, 7) are therefore positioned in a very accurate manner relative to one another, before injecting the overmoulding plastic material. The invention can be used for the production of torque sensors used in the power-steering systems of automobiles.

Abstract: A method for centralising and retaining a molded end coil (20) in a magnet former (12) which includes an oversleeve (24) for retaining the end coil in position, the radially outer (A2) surface of the end coil being of lesser diameter than the radially inner surface of the oversleeve.

Abstract: An electric motor comprising an annular stator core, a resin molding the stator core, a casing member housing the stator core, wherein the casing member has an opening, and the resin is filled into the opening.

Abstract: A coil component having an easily discernible orientation, and a method of producing such a coil component that facilitates the injection of resin. A coil component includes a core with a winding portion, first and second flanges disposed on either end of the winding portion, and a winding accommodating region defined by the winding portion and the first and second flanges, terminal electrodes disposed on the second flange and a winding wound about the winding portion and connected to the terminal electrodes. An insulating resin is formed over the winding at the winding accommodating region. A marker made from a material the same as the insulating resin is provided at outer peripheral surface of the flanges.

Abstract: A split stator is arranged such that a formed edgewise coil is mounted on a teeth of a split stator core through an insulator, and a resin molded portion is formed excepting long ends of the edgewise coil.

Abstract: Method of encapsulating optoelectronic components, by embedding the components to be encapsulated between a first transparent polymer layer and a second polymer layer, which is filled with unactivated foaming agent, and then activating the foaming agent, so that the two polymer layers join to one another, in particular weld to one another, and the components are enclosed between the two polymer layers.

Abstract: A metamaterial that includes a metallic wire and a supporting member. The metallic wire has a length of substantially half the wavelength of electromagnetic waves, and is coiled in the shape of a spring. The supporting member fixes the metallic wire such that the central axis of the metallic wire is parallel in direction to an electric field generated between a signal line through which an electric current flows and a ground. The metallic wire placed in such manner resonates with electromagnetic waves having a wavelength approximately twice as long as the metallic wire, and exhibits a negative dielectric constant.

Abstract: A ground coil device for a magnetic levitation railway that can be manufactured with a high productivity and exhibit less fluctuation in strength, reduced weight, and good recyclability, and a process for manufacturing the device. The ground coil device includes a coil conductor covered with a thermoplastic resin molding material containing 100 parts by mass of a thermoplastic resin, from 20 to 200 parts by mass of an inorganic filler, and from 0 to 25 parts by mass of an elastomer. A process for producing the ground coil device for magnetic levitation railway includes filling the thermoplastic resin molding material into a cavity of a metal mold into which the coil conductor is previously inserted, by an injection molding method, to obtain an integrally molded product.