Abstract: An electronic component comprises an inductive element which includes a pair of zigzag parts, a pair of first terminals connected to one side of the zigzag parts, a connection part connected to the other side of the zigzag parts, an electrode disposed in the middle of the connection part, a second terminal provided on the extensional position of the electrode, and an exterior mold having a gap in the middle in order to expose the fronts of electrode and second terminal.

Abstract: A coil device comprising a bobbin provided at one end thereof with a flange, a wire wound around the bobbin, a pair of terminals provided on the flange and connected to both ends of the wire, and a device for reducing concentration of stress to the ends of the wire during shrinkage and expansion of the bobbin associated with changes in temperature. A method for producing a coil device can include providing a bobbin having a wound wire and a flange provided at one end portion, partially inserting terminals into respective grooves formed in the flange, connecting ends of the wire to the terminals, and moving the terminals within the grooves to produce slack in the wire.

Abstract: A dry type transformer has an iron core, high voltage windings embedded in cast resin, and low voltage windings resin encapsulated. The low voltage winding is constructed with flexible sheet conductors. Insulating material includes an apparatus to secure the windings in place during a vacuum and pressure resin impregnation process. The result is a coil that exhibits high short circuit protection due to the tightly bond conductors comparable to completely resin encased molded transformers at a substantially reduced cost.

Abstract: A small and thin step-up transformer suitable for use in an inverter or the like includes: a bobbin formed of an insulating material having a cylindrical winding shaft; a primary winding wound on said winding shaft; and a secondary winding wound in alignment in multi-layers from the inner side to the outer side thereof; and wherein the primary winding and the secondary winding are separated from each other at a portion of the bobbin to be arranged side by side in the central axial direction of the winding shaft and are electromagnetically coupled to each other.

Abstract: A sensor has a metal case with a sensing coil at one end and a shielded cable extending from the other. In one use it is placed in proximity to rotating machinery to sense imbalance by position change of the shaft. A pair of suitably sized metal cylinders which are precisely interlocked by dielectric material provides for firm mechanical and electrical connections to the inner and outer conductors of the associated shielded cable. In addition a four step injection molding process provides for accurate and secure location of the sensing coil. And at the same time the entire structure because of the injection molding and associated seals is moisture proof. Other uses include temperature and velocity sensing.In an alternative embodiment only a two-step injection molding process is utilized with a somewhat simplified procedure.

Abstract: A solenoid for a solenoid actuator or solenoid valve is encapsulated within a unitary homogenous plastic body which is molded directly about the solenoid coil and the adjacent portion of the solenoid leads so as to seal the coil and leads against the ambient environment and includes a first body portion enclosing and sealing the coil, and an integral second body portion in the form of an externally threaded stem circumferentially surrounding and sealing the adjacent portion of the leads. The externally threaded stem may be used to couple the solenoid to an electrical cable through which the solenoid is energized or to mount the solenoid on a support, such as a barrier wall between a hostile environment to which the sealed solenoid may be safely exposed, and an environment to which the unencapsulated portions of the solenoid leads may be safely exposed.

Abstract: An armature stator comprises an iron core and a coil directly mounted on the iron core. The coil is composed of wound electric wire which has a coating comprising an inorganic material, such as ceramic. A bonding material of the inorganic material is formed over the coil and iron core for filling any gaps and adhering the coil and iron core together into a unitary structure. To improve the reliability of the coil, after the electric wire is wound to form the coil, a filling material comprised of the inorganic material is formed over the coil by vacuum impregnation, and then sintered so as to repair defects in the coating disposed on the electric wire. After the bonding material is formed over the coil, which is directly mounted on the iron core, it is cured under high temperature. The armature stator thus constructed can be used with high reliability in high temperature and high vacuum applications.

Abstract: A separable inductive coupler for transferring electrical power across a dielectric medium using magnetic induction. Its coil geometry allows for easy disassembly of primary and secondary circuits. When primary and secondary coils are mated, an extremely low leakage inductance transformer is formed. This provides for good high frequency operation at high power density. The coupler allows electrical power transfer without metal-to-metal contact. The design allows easy removal of the primary or secondary coil from the transformer. The coil geometry has very low leakage inductance and very low high-frequency resistance which allows high frequency operation. The power transfer density is much higher than previously achieved with separable inductive couplers. Approximately 6000 watts has been transferred through a version of the present separable inductive coupler having a volume of 25.8 cubic inches, yielding a power density of 230 Watts/cubic inch.

Abstract: Three phase transformer, e.g. distribution transformer, comprising three frame shaped winding assemblies, each containing primary and secondary windings, two of said assemblies being substantially identical and juxtaposed to form a center leg having substantially circular cross section, and a third winding assembly surrounding the two said assemblies, and forming, together with the outside half legs of said winding assemblies, two outside legs, each having substantially circular cross section, the three winding assemblies being interlinked by hollow, cylindrical cores wound from ferromagnetic strip material and surrounding each of the three legs.

Abstract: A small, lightweight, efficient, very low cost AC adaptor for consumer electronics applications is realized by combining a switching regulator integrated circuit along with a leadframe adapted to mount the switching regulator integrated circuit off-center, a single-sided printed circuit board and high frequency ferrite cores. These components are assembled onto a substrate, such as a printed circuit board, by means of well-known, low-cost automatic insertion assembly machines. The novel structural aspects result in formation of a transformer from the leadframe and traces on the printed circuit board. The power supply resulting from this assembly method may be small enough to be molded into the plug portion of a standard AC power cord.

Abstract: A coil has one or more layers of primary and secondary windings about a bore liner, with the primary and secondary windings separated by a winding of glass threads. The coil is heated in an oven to first drive off the volatiles of the binder forming part of the ceramic insulation for the primary and secondary coils and which volatiles pass through the winding of glass thread. The coil is further heated so that portions of the glass fibers forming the threads vitrify with the non-vitrified remaining portions retaining their well-defined, discrete fiber characteristics, whereby they extend through the vitrified glass to seal the coil, reinforce the coil against vibration and shock, and enable a dimensionally compact coil.

Abstract: An electromagnetic solenoid comprises a coil wound around a coil case and a plunger inserted into the coil so as to be slidable in the axial direction, wherein a tape impregnated with a thermosettable resin is wound on the trunk portion of the coil case and the coil is wound on the wound tape.

Abstract: A high voltage coil manufactured by alternately winding coils and mounting rigid insulating tubes on a coil form having end plates with terminals. After each coil is wound with its ends terminated at the end plates, a first axially slitted insulator tube is snapped over the coil with about a one-quarter inch gap and a second tube with no gap is snapped over the first rotationally displaced 180 degrees enclosing the gap which forms a flow conduit. Another coil is wound on the second tube and the process is repeated to form as many as six coils. Potting material is applied to the completed assembly and vacuum impregnated, and the tube conduits form flow paths to achieve complete impregnation.

Abstract: An inductance coil which is completed by casting resin around the body comprising a bobbin wound with a coil and a couple of U-shaped cores inserted in a center hole of the bobbin with the end faces adherent to each other to form a closed-loop magnetic path. The couple of cores are coated with mold releasing agent to assure the adhesion of the end face.

Abstract: An ignition coil has a high tension winding divided into sections, each of which is wound in one of a plurality of winding compartments formed in an insulating body and which are spaced apart from each other by insulating compartments. The various sections of the high tension winding are connected in series using the wire of which the winding itself. The high tension sub-assembly is encapsulated in an insulating envelope. The high tension or secondary sub-assembly is impregnated with an adhesive varnish before being encapsulated in a plastics material, the encapsulation being carried out by surface moulding.

Abstract: A toroidal core is mounted on an alignment disc having uniformly distributed circumferential notches or holes therein. Wire is then wound about the toroidal core in a uniform pattern defined by the notches or holes. Prior to winding, the wire may be placed within shrink tubing. The shrink tubing is then wound about the alignment disc and core and then heat-shrunk to positively retain the wire in the uniform position on the toroidal core.

Abstract: A molded coil directly connected face to face to a conductor pattern of a circuit board, for eliminating unnecessary dimensions for pulling out end parts of the coil as face-to-face connection terminals, comprises at least one coil arranged along a vertical direction in which the coil is extending and buried in a synthetic resin body, a lower end part of the coil bent in the resin body in a horizontal direction so as to be orthogonal with the vertical direction and exposed to the outside of the resin body and end parts except the lower end part of the coil exposed to the outside of the resin body parallel to the vertical direction and bent outside in the horizontal direction, to form a face-to-face connection terminal, respectively.

Abstract: A method of constructing a distribution transformer of the type having a magnetic circuit in the form of one or more hollow coils and having primary and secondary windings by coiling an electrically insulated wire. The wires are then juxtaposed to form primary and secondary windings while interposing a flat insulating sheet material between adjacent coils. A cooling liquid is associated with the primary and the secondary coil windings and a rigid support frame is formed above these windings. A ferro-magnetic steel ribbon is coiled about at least one leg of the support frame containing the primary and secondary windings whereby to form a magnetic circuit.

Abstract: A coil is wound either with insulated wire or space wound with uninsulated wire and subsequently coated with a solder resist or insulating material. If insulated wire is used, the insulation is removed from the wire either during or after winding at predetermined locations to match the location of connection pads in a conductive pattern on a substrate. The coil is appropriately aligned and laid down on the substrate and an attachment technique is used to form an electrical connection between the exposed areas of wire and connection pads on the substrate. Alternatively, uninsulated wire may be used, which is space wound and coated with a solder resist or insulating material. The uninsulated wire may either be masked prior to coating or the insulating material may be removed following coating to form exposed connection locations on the coil corresponding to the location of the connection pads on the substrate.

Abstract: A high voltage electrical winding for shell form transformers is disclosed that reduces eddy current and circulating current losses within the winding. The winding is fabricated from an elongated conductor bundle that is spirally wound into a plurality of turns. The conductor bundle is formed from a multiplicity of enamel coated elongated conductor strands arranged in side by side relation. Each of the conductor strands has a rectangular cross section with a thickness of less than approximately 40 mils between contacting surfaces. The strand's cross sectional height is preferably less than 120 mils. The conductor strands are mounted side by side such that their respective contact surfaces abut. The conductor bundle is preferably wrapped in an adhesive tape to give the bundle some structural support and to provide insulation between winding turns. The disclosed winding also has very good mechanical strength and impulse distribution.

Abstract: A heat-distributing winding for the equalization of uneven heating of the winding parts of an annular core transformer including a winding concentric with the core and made from juxtaposed turns of wire-shaped heat-conducting material substantially perpendicular to and in heat-conductive contact with, but electrically insulated from the winding parts extending along the cylindrical external surface of the core and mainly in the generatrix direction of said core. The heat-distributing winding is applied to the inner side of or on either side of said above mentioned winding parts of the transformer and consists of turns electrically insulated from each other and consisting of wire of for instance rectangular cross-section.

Abstract: Disclosed is a water-cooled winding for an electromagnetic stirrer, which comprises a coil including a plurality of wound flat type wires having a wire-insulating turn insulation, and a porous polyamide fiber having an air permeation rate not higher than 25 seconds/100 cm.sup.3 of air covering the periphery of the coil, which is impregnated with an epoxy resin composition. In this water-cooled winding, the polyamide fiber is sufficiently impregnated with the epoxy resin composition and this epoxy resin composition is cured stably and assuredly. Accordingly, the mechanical rigidity of the winding is sufficiently high, and the water resistance of the winding is highly improved and is maintained for a long time, with the result that the life of the winding is greatly prolonged.

Abstract: A coil for arrangement in slots in a stator or rotor of an electrical machine, in particular a high voltage coil, comprising a bundle (17) of a plurality of conductors (18) located adjacent to each other and provided with a conductor insulation (19) for insulation of the conductors from each other as well as a main insulation (14) surrounding the bundle for insulation of the bundle against the machine slot. The main insulation consists of a wrapping of a tape- or sheet-formed insulating material wound in several layers around the bundle and comprising a layer with small mica flakes which, as well as the spaces between layers of mica flakes in the wrapping, contains a cured impregnating resin. At least that part of the impregnating resin located in the spaces between mica layers contains particles of a filler with an intrinsic thermal conductivity of at least 5 W/mK, such as aluminium oxide or boron nitride, and with a grain size of the particles of 0.1-15 .mu.m in at least 90 percent of the filler.

Abstract: The commutating poles of vehicular-type d-c motors, for example for trolley buses or trolley cars, are made by winding, on edge, a copper strip, permitting the wound copper strip to resiliently, spring-like expand so that the individual spiral loops thereof will be slightly spaced from each other, and then exposing the copper strip in a fluidized bed to an insulating powder, for example polyethylene or polyurethane, which is subsequently cured in a hardening or sintering process.

Abstract: Optical-waveguide coils are used in rotation rate measuring instruments. To protect the optical-waveguide coil (1) from external influences, such as sound waves, pressure, and temperature changes, which may result in measurement errors, it is wound on a coil form (2) of soft elastomer under low tension. The coil unit so formed (1/2) is then placed in the annular groove (4) of a housing (3/5). Spacers at the coil form (2) position the coil unit (1/2) in the annular groove in such a way that the coil (1) is exactly in the middle of the annular groove (4). The remaining free space of the annular groove (4) is then filled with a sealing compound (6) in a vacuum. The sealing compound also spreads between the windings of the coil (1). It is preferably the same material as that from which the coil form (2) is made.

Abstract: A coil is wound either with insulated wire or space wound with uninsulated wire and subsequently coated with a solder resist or insulating material. If insulated wire is used, the insulation is removed from the wire either during or after winding at predetermined locations to match the location of connection pads in a conductive pattern on a substrate. The coil is appropriately aligned and laid down on the substrate and an attachment technique is used to form an electrical connection between the exposed areas of wire and connection pads on the substrate. Alternatively, uninsulated wire may be used, which is space wound and coated with a solder resist or insulating material. The uninsulated wire may either be masked prior to coating or the insulating material may be removed following coating to form exposed connection locations on the coil corresponding to the location of the connection pads on the substrate.

Abstract: A holding device for wound toroidal cores is formed of a carrier plate and a centering arbor extending from the carrier plate into the inside of the wound core. The wound core is fixed in place on the arbor by a casting compound.

Abstract: A process for electrodepositing mica and a water soluble anionic resin binder, such as a modified polyester resin, is disclosed as a means for applying a heavy coating of a high-voltage, mica-bearing electrical insulation onto uninsulated and porous mica tape-insulated portions of electrical connections in dynamoelectric machines. The electrodeposited mica coating is subsequently impregnated with a suitable resin, such as an epoxy or polyester resin, concurrently with the impregnation of other conventional insulations in the machine. Alternatively, deposition and impregnation of the connection insulation can be performed prior to installing the connection into the machine.

Abstract: A symmetrical bobbin especially adapted for the automatic manufacture of electrical coils. The bobbin, formed of high-strength plastic material, comprises first and second lips formed at terminal ends thereof and first and second flanges spaced inwardly from the lips. The bobbin surface between the flanges defines a main coil winding space and the bobbin surfaces between the lips and corresponding flanges define first and second terminal winding spaces. Immersion soldered terminal connections, of high physical strength, durability and electrical conductivity, are formed by extensibly wrapping electrical wire from the main coil about the terminal winding spaces and subsequently immersing the wire-wound terminal winding spaces in molten solder to provide a circumferential bond of unitary structure for terminal connection.

Abstract: In a relay which has a coil body as a base body, an insulating cap of foil material is inverted over the wound coil body. The insulating cap is adapted to the outer contour of the wound coil and having a semi-cylindrical center section covering the upper half of the winding and pockets adapted to the coil body flanges. As a result thereof, the insulating cap is provided with good stability and is therefore protected against deformation and damage.

Abstract: An electromagnetic actuator including a stator and an armature having opposed flat faces which are movable relative to each other, grooves formed in the flat face of the stator facing the flat face of the armature, with endless coils received in the grooves, and bore hole formed in the stator for fluid communication between the grooves, for allowing resin to be poured in the bore hole and thus fill the grooves with the endless coils therein.

Abstract: A high voltage transformer includes at least one secondary coil mounted on an insulating support assembly and having the start lead of the secondary coil disposed proximate to the transformer core with a finish lead disposed at the perimeter of the coil. The finish lead is connected to ground potential and the start lead is provided at the high voltage potential of the transformer, thereby minimizing the insulation requirements of the transformer. The insulating support assembly for the secondary coil includes flanges at the opposite ends thereof to define a winding space for the secondary coil. Each of the flanges includes a channel formed therein for providing a passageway for the high voltage start lead of the secondary coil that extends from the inside layer of the secondary coil to above the edge of the flange. The flange also has a recess that extends between the opposite edges thereof for receiving and insulating sheet member.

Abstract: A coil assembly includes a first winding for circumferentially surrounding at least a portion of a leg of a transformer core, a second winding spaced from and circumferentially surrounding at least a portion of the first winding, first supports, such as axially extending insulative rods, disposed between the first and second winding, for inhibiting axial motion of the second winding relative to the first winding and a second support disposed about at least a portion of the outer periphery of the second winding for inhibiting radial motion of the second winding relative to the first winding. Encapsulating material, such as an epoxy resin having glass fibers disposed therethrough, is disposed between the first winding and the leg, between the first and second winding and disposed about the second support for forming a monolithic structure. In a transformer including such a coil assembly, the leg and conductors forming the windings may be fluid cooled.

Abstract: A magnetic core containing amorphous metal, suitable for use with electrical inductive apparatus, such as transformers, and methods of constructing such a magnetic core. The desired physical dimensions of the magnetic core are maintained, without adversely stressing the core, by a composite, conformal coating applied to the core edges. The composite coating includes a rigid high strength outer structure and a low stress, adhesive inner structure which cooperatively provide mechanical support and stress protection for the magnetic core, while maintaining its configuration.

Abstract: Secondary winding configurations and methods particularly applicable for toroid transformers are described for winding secondary windings over the indexed primary winding and toroidal core. The secondary winding is formed in the configuration of a multifilar winding of a plurality of coplanar parallel filaments with a first elongate strip of electrically insulating material bonded to the filaments on one side and a second elongate strip of electrically insulating material bonded to the filaments on the other side and to the first elongate strip. The resulting electrically insulated multifilar strap winding contains the filaments in substantially parallel coplanar relationship. The multifilar strap winding is wound around the toroidal core in substantially equally spaced turns. The strap winding maintains the filaments substantially in equally spaced relationship relative to each other over irregular surfaces and compound curvature of the toroidal core without crossover.

Abstract: A high voltage transformer is provided for the voltage employed in the line deflection of an electron beam in a television receiver. The secondary high voltage winding is inserted into a case via an opening running parallel to the axis of the primary and secondary winding and is disposed in the case separate from the primary winding and is surrounded by a cast plastic resin. Preferably, the secondary winding body snaps into elastically supported protrusions disposed at the case. The plastic resin is filled into position through said opening. The high voltage connection is immersed into the plastic resin and is then led outwardly.

Abstract: The secondary winding (15) and the coil body (14) carrying it are manufactured in a chambered realization, and the radial extension (height) of each chamber winding (29) decreases toward the higher chamber potential in accordance with the law of geometrical progression, so that the insulating distance (30, 31) between the secondary winding (15) and areas of the ignition coil that carry a lower potential increases with an increasingly higher chamber potential.As a result, the volume and the weight of the ignition coil are reduced, while the electrical output remains the same.

Abstract: Methods of constructing a void-free, cellulose-free electrical winding insulated with a solid resinous insulation. The method includes forming a plurality of conductor turns on a substrate, with each conductor turn being immersed in liquid resinous insulation as it is formed, to provide a void-free intermediate structure. The void-free aspect of the intermediate structure is maintained up to and including the final step of the method by building solid insulation, thin layer upon thin layer, from the liquid resinous insulation, while the conductor turns are being formed, with the solid insulation, as it is formed, providing a solid substrate for the continued application of liquid resinous insulation and subsequent conductor turns of the winding.

Abstract: A method of constructing an LC network, and the resulting LC network manufactured by cutting and removing a predetermined pattern from a first and a second conductive sheet, leaving on each sheet a generally coil-like configuration of windings with a sufficient number of interconnections between the adjacent windings to add rigidity to the sheets, laminating these conductive sheets to opposing faces of a non-conductive sheet, thereby forming at least one capacitor, cutting and removing a pre-determined pattern from the lamination eliminating at least some of the interconnections and leaving a conductive path on the conductive sheets which is in the configuration of a coil.

Abstract: An improved coil construction for the voice coil motor of a transducer positioning system of a magnetic disk drive results in increased coil strength while eliminating the tendency of volatile materials associated with either the assembly process or the coil insulation to be entrapped between turns. Insulated aluminum ribbon wire having a rectangular cross-section is edge wound on a mandrel with adjacent turns being bonded together and then subjected to a curing process. By subjecting the ribbon wire to a knurling process prior to winding, the flat surfaces of the ribbon wire are provided with a plurality of knurl prints on each side which extend between opposite edges of the wire in a direction transverse to the lengthwise dimension of the ribbon wire. After winding, the knurl prints serve as interturn vents to prevent entrapment of any volatile materials generated during the curing process. The construction substantially doubles the tensile strength of the coil.

Abstract: A dry-type transformer cast into casting resin, includes windings, a main leakage canal, at least one of the windings being subdivided into coaxial winding parts spaced apart from each other defining an additional axial cooling canal therebetween, separate inner and outer casting resin bodies each having end faces and being cast around a respective one of the winding parts, reinforcements formed on diametrically opposite outer surface regions of the outer casting resin body for receiving axially extended connecting conductors for electrically wiring the winding parts, line terminals and tap terminals disposed on respective reinforcements, and elastic blocks common to all of the windings and winding parts between which the winding parts of a respective winding are clamped and metallically interconnected in front of the end faces of the casting resin bodies.

Abstract: A dry type, air cooled transformer having a mitered magnetic core and a compression bonded coil. The coil on each of the core legs is generally rectangular in shape and comprises a plurality of layers of wound conductor with the conductor layers in the end portions of the coil being spaced apart to form a plurality of air ducts for the passage of cooling air therethrough. The conductor layers in each of the side portions of the coil are compressed and then bonded together in their compressed state by means of a heat cured adhesive coated on opposite sides of the sheets of insulation between adjacent layers. This compression bonding of the coil sides squares up the inner and outer surfaces of the coil so as to improve the coil and core space factors thereby allowing a smaller core. Conversely, compression bonding allows higher output power ratings to be achieved by packing added conductor material through the same size core window.

Abstract: Several embodiments of coil assemblies suitable for a variety of uses are disclosed herein all of which employ spiral windings which minimizes coil layer-to-layer voltage gradients to levels which conventional enamel wire insulation is able to withstand. In one embodiment a spiral winding is fabricated in strip form using a continuous strand of wire secured to a continuous ribbon-like substrate by an adhesive composition which may be provided on the wire so as to form a plurality of spiral windings on segments or portions of the substrate, each winding having one turn in each radial layer. The substrate will include other segments located between each winding portion to provide insulating means for the spiral windings and for the transition of the wire as it passes to the next successive winding containing segment.

Abstract: An induction heating coil having fluoroplastic coated polyimide tape wrapped windings for providing a bonded, solid monolithic structure. The induction heating coil includes a cooling fin of predetermined length extending in interleaved relationship between a plurality of consecutive turns of current-carrying coil windings. A plurality of fluoroplastic coated polyimide sheets are fused to the coil body between the coil body and a fluoroplastic face sheet forming the outer wear surface of the induction heater coil, thereby providing a non-stick surface for release of hot melt adhesives.

Abstract: A wire having conductor core, insulating film formed on the conductor core and adhesive film formed on the insulating film is closely and fixedly wound by a predetermined number of turns. Thus, a coil for an electric motor is obtained. A pair of electrodes are formed by stripping portions of the insulating film and portions of the adhesive film formed on the insulating film.

Abstract: A method of making a cellulose-free electrical winding having a tubular configuration in which layers of insulating resin and conductors are alternately disposed in a concentric pattern, with opposite edges of the conductor turn layers being coated with overlapping layers of resin. The resin is applied as a liquid in thin layers as the winding is being formed, and the liquid resin is instantly gelled to provide mechanical support for the next winding layer.

Abstract: An economical and light-weight molded coil structure wherein sheet-form electrical insulator layers containing a thermosetting resin are wrapped around the inner and outer peripheries of a coil to function as a casting mold, and end-enclosing resin layers are applied to the both end faces respectively of the coil not covered with the sheet-form insulator layers. A gas is charged to be sealed in the coil.

Abstract: Transformer, including an iron core, high voltage and low voltage windings, at least one cast resin body completely embedding, holding and insulating the windings, the cast resin body having cooling channels formed therein and having additional channels formed therein being separated from the cooling channels, and insulating gas filling the additional channels.

Abstract: A method of constructing an inductive-capacitive (LC) network is disclosed in which a predetermined pattern is cut from a metallic sheet to provide a multi-turn, essentially spiral-like configuration in which a plurality of interconnecting regions are left between adjacent turns. A pre-laminate is then formed by laminating one surface of the configured sheet to a surface of a sheet of dielectric material. A completed multi-turn inductor is formed by a second cutting operation in which the remaining interconnecting regions between the adjacent turns are removed. The LC network is completed by laminating a second metallic sheet to a dielectric layer overlying the completed multi-turn inductor. The first and second cutting operations and assembly of the respective sheets are performed such that any burrs resulting from the operations are directed away from the interlying sheet of dielectric material, thereby avoiding problems due to shorting out between the two metallic sheets.

Abstract: Secondary winding configurations and methods particularly applicable for toroid transformers are described for winding secondary windings over the indexed primary winding and toroidal core. The secondary winding is formed in the configuration of a multifilar winding of a plurality of coplanar parallel filaments with a first elongate strip of electrically insulating material bonded to the filaments on one side and a second elongate strip of electrically insulating material bonded to the filaments on the other side and to the first elongate strip. The resulting electrically insulated multifilar strap winding contains the filaments in substantially parallel coplanar relationship. The mulfifilar strap winding is wound around the toroidal core in substantially equally spaced turns. The strap winding maintains the filaments substantially in equally spaced relationship relative to each other over irregular surfaces and compound curvature of the toroidal core without crossover.