Abstract: A jig (10) is used to form a coil (50) for an electrical machine. A plurality of conductive wires (56), each covered in a heat-curable electrically insulated material, are wound around a bobbin (12). Each succeeding winding in contra-wound relative to the previous winding, with the first turn (16) of each succeeding winding overlaying the last turn (5) of the previous winding. Undeformable electrically insulated inserts (54) are inserted into the windings before heating and compressing the coil (50) in the jig (10).

Abstract: A power or regulating transformer with voltage regulator includes regulating windings made of a flexible conductor having an electric field containing mechanism that forces the electric field due to the current in the winding to be contained within the flexible conductor. Since virtually no electric field is to be found outside the flexible conductor of the regulating winding, the regulating winding may be formed without having to consider the electric field distribution, thus providing for a transformer with a favorable regulating winding design.

Abstract: An inductor comprises a substrate comprising a semiconductor material, a first dielectric layer over the substrate, a magnetic layer over the first dielectric layer, a second dielectric layer over the magnetic layer, and a conductor over the second dielectric layer.

Abstract: A method of manufacturing a coil unit includes the first step of disposing a coil between a first frame and a second frame, the second step of pouring liquid resin into between the first frame and the second frame with the coil disposed therebetween, and the third step of curing the liquid resin to thereby fix the first frame, the second frame and the coil to one another.

Abstract: A transformer coil is produced by forming a sheet of composite material over a plurality of annular shaped support plates to form an inner layer. A coil is wound around the inner layer. An outer layer is formed by wrapping a sheet of composite material over the coil. The outer layer is mechanically attached to the coil. A base is attached to the coil assembly and epoxy is used to encapsulate the coil. The epoxy forms a bond with the inner and outer layers, which become an integral part of the transformer coil.

Abstract: A high voltage transformer includes an E-shaped core having grooves into which electrical parts are inserted, an I-shaped core supporting the E-shaped core, and an insulating element inserted between the E-shaped core and the I-shaped core to insulate the electrical parts. The electrical parts are primarily insulated by the insulating element inserted into the transformer, so that a conventional insulation process may be shortened. Additionally, low-cost insulating papers may be used to insulate the electric parts, so that the manufacturing cost of the transformer may be reduced.

Abstract: An externally adjustable RF impedance matching mechanism comprises an upper lid and a base containing a circuit element board therebetween. One or more than one precise adjustment device for adjusting impedance value are provided under the upper lid. Impedance adjustment is carried out by manually turning setting screws associated with the aid of spring force. Heat conductive material is coated between the circuit board and the base so that the device is able to operated at a high power. The expensive material such as ceramic is used in forming the coil board only so that material and the production cost are low.

Abstract: A fault current limiter (FCL) comprises: an air core flat clock spiral inductor comprising wound electrically conductive material and insulated turns; and two terminations configured for attaching the spiral inductor in series with a power carrying conductor.

Abstract: A technique is provided for insulating a winding or coil for an electrical machine such as a motor. The coil is wound and placed in a taping station. Multiple layers of insulating tape are applied along an end region with leads bent back from the end region. The taping station permits the leads to be then placed over the insulated end region, and the main body region of the coil is similarly taped in a continuous uninterrupted manner. The tape wrap pitch may be varied along certain regions, where increased dielectric strength is desired. Following the insulating tape application, an armor tape may be applied over both the end region and the main region of the coil in a continuous uninterrupted manner. The coil can then be finished and assembled in a machine such as an electric motor stator.

Abstract: A method of producing a chip inductor including the steps of inserting a conductive wire made of a metallic wire into a metallic mold, supporting both end portions of the conductive wire on support portions provided on inner surfaces of the metallic mold so as to position the conductive wire in the approximate center portion of the metallic mold, casting magnetic ceramic slurry into the metallic mold, molding the ceramic slurry case in the metallic mold by wet pressing to obtain a molding body having the conductive wire embedded therein, firing the molding body, and forming external electrodes on both end surfaces of the fired magnetic core such that the external electrodes are connected to both end portions of the conductive wire.

Abstract: A winding for a transformer or coil includes a ribbon electrical conductor and at least one ribbon insulation material layer fitted thereto or applied as ribbon material thereto. The conductor and the insulating material layer are wound to form turns around a winding core along a winding axis. The individual turns of the winding have a predetermined winding angle with respect to the winding axis. A number of turns are located axially alongside one another form one layer, and at least two radially adjacent layers of turns are provided. A first layer of turns is radially adjacent to a second layer produced by changing the winding direction by folding the electrical conductor and the insulating material layer. The total angle, which is produced by the folding, between the longitudinal direction of the ribbon insulating material in the first layer and the corresponding direction of the second layer corresponds to twice the winding angle.

Abstract: A functional material—composite structural magnetic core is the magnetic core mainly consisting of magnetic material and having regular geometric form. It includes a box with a slot cavity and through hole. The inner magnetic core is installed inside the cavity of the box. It is characterized by: there are multiple inter-layers inside of the cavity of the slot. The inter-layers divide the slot cavity into the multiple continued ring slot and inside the ring slot many inner magnetic cores are installed respectively. The advantages are: wide application frequency band, large application temperature range, expanded electromagnetic compatibility. The continued stability and sudden change of the electromagnetic characteristics can meet requirements of the electronic technology. The sensing and sending of power transferred signal and control of noise wave etc. showed its composite excellent performance, corresponding and matching characteristics.

Abstract: Metallic coils sheets (34, 36, 38) are planar and include center windows (34a, 36a, 38a). Slits (34b, 36b, 38b) extend outward through the respective sheets from the windows. Connection terminals (34c, 34d; 36c, 36d; 38c, 38d) are provided on the sheets at locations facing across the respective slits. The metallic coil sheets are stacked, and adjacent ones of the stacked metallic coil sheets are electrically connected by means of the connection terminals. A core (60, 62) is disposed in the windows of the stacked metallic coil sheets. The metallic coil sheets are individually covered with an insulating coating.

Abstract: The present invention relates generally to provision of electrical power downhole to power tools such as pumps, valves, motor-driven drilling tools, grapples and the like. More particularly, the present invention relates to the provision of electrical power through cables included within the walls of high density plastic tubing used in completion or production techniques in some oil and gas production settings, commonly referred to as “coiled” or “endless” tubing.

Abstract: Toroidal transformer and inductor configurations are described that allow for greater heat transfer away from internal device components. The inventive transformer allows for higher thermal and electrical efficiency, as well as for more efficient use of expensive components, such as copper wire. In one embodiment, a toroidal transformer provides access for cooling air by forming the primary winding from a single layer of thick wire and a secondary winding of few turns such that most of the primary winding is exposed to air flow. In another embodiment, a heat sink is positioned between the core and primary windings to conduct heat away from the transformer.

Abstract: A method of manufacturing an inductor includes the step of molding a magnetic material formed by kneading a magnetic material and a resin to form a magnetic material compact body in which the internal conductor is partially exposed from the external surface thereof. Then the surface of the magnetic material compact body is plated to form the external electrodes including a plated metal film and connected to the internal conductor. The surface of the magnetic material compact body is roughened, and then the external electrodes are formed via plating.

Abstract: A method of manufacturing an improved comb for a disk wound transformer. The method comprises the steps of providing a web of cellulose material; removing a portion of the cellulose material to create a plurality of longitudinal slits along the length of the web, wherein the longitudinal slits have a fixed length and width; and folding the web along a line proximate the midpoint of the length of each of the longitudinal slits such that the cellulose material adjacent the longitudinal slits defines a plurality of tooth members.

Abstract: An electrical conductor winding (70) comprises a plurality of laminates of electrical insulation (72). Each laminate of electrical insulation (72) has a slot (78) on one surface (76). Each laminate of electrical insulation (70) has an electrical conductor (82) arranged in the slot (78). An electrical connector (84) connects the electrical conductor (82) in one laminate of electrical insulation (78) with the electrical conductor (82) in an adjacent laminate of electrical insulation (72). The laminates of electrical insulation (72) are arranged such that the surface (74) of one laminate of electrical insulation (72) abuts and is bonded to the surface (76) of an adjacent laminate of electrical insulation (12). The laminates of electrical insulation (12) comprise a glass-ceramic material. The electrical conductor windings allow active magnetic bearings, electric motors and electric generators to be used at temperatures up to 500° C. for example in gas turbine engines.

Abstract: A high-voltage winding is described for use in a dynamoelectric machine. The high-voltage winding includes an electrical conductor (12), an insulator (14) surrounding the electrical conductor, and an electrically conductive layer (16) surrounding the insulator. The insulator (14) may include a tape (18) arranged to define a wrapped layer. A double-sided tape may be provided that includes a flexible tape substrate (20) with an inner major surface (22) adjacent the conductor (12) and an outer major surface (24) opposite the inner major surface. An inner silicate layer (26) may be secured to the inner major surface and an outer silicate layer (28) to the outer major surface. A single-sided tape may also be provided between the conductors and double-sided tape.

Abstract: A method for fabricating an inductor which includes a core, a shield and a length of epoxy tape is provided which includes the steps of winding the wire into a coil onto the core, wrapping the epoxy tape around a perimeter of the core, installing the core including the coil and epoxy tape into the shield, and heating the inductor causing the epoxy tape to bond to the shield. An inductor incorporating the method is also described.

Abstract: An advanced microelectronic coil device incorporating a toroidal core and a plurality of sets of windings, wherein the windings are separated by one or more layers of insulating material. In one embodiment, the insulating material is vacuum-deposited over the top of a first set of windings before the next set of windings is wound onto the core. In this fashion, the insulating material insulates the entire first winding from the second without the need for individual insulation on each of the windings, or the use of margin tape. The use of the vacuum-deposited insulating layer(s) provides a high degree of dielectric strength, yet consumes a minimum space since the insulation on each winding is minimized. The toroidal core is also optionally provided with a controlled thickness gap for controlling saturation of the core.

Abstract: A choke coil has small difference of wire wound resistances between coils to obtain sufficient unbalance attenuation amount, superior in workability in winding and reduced leakage inductance and line capacity. The choke coil includes first and second coils divided into first and second segments wound on a single spool disposing intermediate insulations layers between respectively adjacent coil segments. The coil segments of the first and second coils are wound alternately. The first coil segment of the first coil and the second coil segment of the second coil being wound in a first winding number and the second coil segment of the second coil and the first coil segment of the second coil being wound in a second winding number. The second winding number being greater than the first winding number for reducing difference of winding resistance between the first and second coils less than or equal to 4%.

Abstract: An electric device comprising at least one core (5, 10) of magnetic material and a high-voltage winding (16) in the form of an electric conductor wound around the core, and a method for manufacturing such a device is described. The device comprises a first insulating layer (14) of a solid, electrically insulating material which encloses the core (10) and which is arranged b between the core (10) and the high-voltage winding (16), and a second insulating layer (18) of a solid, electrically insulating material which encloses the high-voltage winding (16). a semiconductive layer is arranged on both sides of each of the electrically conductive layers.

Abstract: A method for producing an inductor having an internal conductor includes coating an internal conductor with a covering material, placing the internal conductor coated with the covering material in a shaping mold, and filling a material around the internal conductor so as to form a compact unbaked chip element with the internal conductor provided at a predetermined position. The unbaked chip element is then baked in order to eliminate the covering material so as to form a gap around the internal conductor.

Abstract: Three thin-film coils having insulating layers therebetween are laminated on the coil winding portion of the core member. A terminal electrode is electrically connected to the end portion of the third thin-film coil. A terminal electrode is electrically connected to the end portion of the first thin-film coil through the lead-out opening portions and separated areas. In this way, the thin-film coils are electrically connected in series between the terminal electrodes. Then, in the thin-film coils, the winding directions of the neighboring coils having an insulating layer therebetween are opposite to each other.

Abstract: A low noise, compact and low cost electric power converter employing a compact common mode transformer, and incorporating a line filter can reduce a leakage current, and can maintain predetermined leakage current reduction effect even if installation condition of the electric power converter or a characteristics of a semiconductor switching element is varied. The electric power converter including a capacitor, a first electrode, a second electrode, a first magnetic body, on which the first electrode and the second electrode are wound to form an LC composite element, connecting electrodes electrically connected to respective of both ends of the first and second electrodes, a second magnetic body for interlinking both ends of the first magnetic body, a coil wound around the second magnetic body in the same winding direction as the first and second electrodes wound around the first magnetic body and a resistor for shorting the output of the coil.

Abstract: A method for fabricating an inductor which includes a core, a shield and a length of epoxy tape is provided which includes the steps of winding the wire into a coil onto the core, wrapping the epoxy tape around a perimeter of the core, installing the core including the coil and epoxy tape into the shield, and heating the inductor causing the epoxy tape to bond to the shield. An inductor incorporating the method is also disclosed.

Abstract: A magnet wire having differential build insulation for use in transformer coils is disclosed. The wire has a rectangular conductor with an insulation that is thicker on the top and bottom surfaces of the wire than it is on the sides. With the thicker coating on the top and bottom, the wire can be used in layer wound distribution transformer coils, both high voltage wire wound coils and low voltage wound coils, without needing additional insulation between the layers of the winding.

Abstract: In at least one shielded core wire, a first conductive core wire is covered with a first insulating sheath. A conductive foil covers the at least one shielded core wire. A second insulating sheath covers the conductive foil. In a branch wire, a second conductive core wire is covered with a third insulating sheath. A part of the second insulating sheath and a part of the third insulating sheath are thermally fused so that the conductive foil and the second conductive core wire are electrically connected.

Abstract: A magnetic device and a method of manufacture therefor. In one embodiment, the magnetic device includes: (1) a bobbin having a winding guide and molded-in margins proximate opposing inside flanges of the bobbin, each of the opposing inside flanges having at least one notch formed in an inside face of each of said opposing inside flanges; (2) an inner winding wound about the winding guide and between the molded-in margins; (3) an outer winding wound about the inner winding and the winding guide and between the flanges; and (4) an insulating plate, provided in the at least one notch and interposed between the inner and outer windings, a thickness of the insulating plate providing a predetermined creepage distance between at least one lead of the inner winding and the outer winding.

Abstract: Winding assemblies for use in transformers include one or more foil strips and insulation covers arranged to provide electrically insulated winding and breakout portions. The winding assemblies may be constructed so as to meet creepage distance and other requirements in a margin free coil design transformer.

Abstract: A chip inductor has a coiled conducting wire and a magnetic core which is formed by sintering and in which the coiled conducting wire is embedded. Both end portions of the coiled conducting wire are exposed to both end surfaces of the magnetic core in an arcuate or similar shape. External electrodes are coated on both the end surfaces of the magnetic core and are connected to both end portions of the coiled conducting wire.

Abstract: A meandering winding magnetometer (MWM) includes a meandering primary winding and at least one sensing winding or coil on a membrane to be pressed against a test surface. The membrane may be supported on a flexible carrier which is translatable into a probe. Abutments in the probe press the carrier against the test surface but allow the carrier and membrane to conform to the test surface. One MWM circuit includes meandering primary and secondary windings. The return leads from the secondary winding return to connector pads in close alignment with the test array, while leads from the primary winding are spaced at least one wavelength from the array. In another MWM circuit, individual sensing loops are positioned within the meandering primary winding. The MWM circuit may be provided on an adhesive tape which may be cut to length.

Abstract: A stationary induction apparatus superior in insulating ability against a surge voltage includes a coil piece on a line end side surrounded by one electrostatic shield insulating layer. The coil piece and electrostatic shield insulating layer, together with another coil piece, are surrounded by another electrostatic shield insulating layer, thus forming a successively nested configuration. Each of the electrostatic shield insulating layers includes an electrical insulating layer of pressboard and first and second conductive layers respectively located on inner and outer surface sides of the electrical insulating layer, The capacitance of each of the electrostatic shield insulating layers is adjusted to control an electrical potential distribution upon application of a surge voltage.

Abstract: The inventive coil comprises a coil body (1) on which an exciter winding (7) is arranged. A peripheral insulation winding (8) consisting of an insulating fiber is formed over the exciter winding, the individual windings of the insulating winding being bonded to each other in order to form a continuous insulation layer. The insulation winding can be made up of a mineral fiber impregnated with duromer resin or a thermoplastic fiber which has been melted on by subsequent heat treatment.

Abstract: A transformer and method of making a transformer is disclosed. The transformer has a magnetic core, a first winding and a second winding. The first and second windings are wound about the core, and an insulating jacket, which includes a plurality of protrusion, mounted about the core. One of the first and second windings is wound about the insulating jacket. The core is preferably a toroid core in one embodiment. Some of the anchors are on the inner diameter of the insulating jacket, and other on the outer diameter of the insulating jacket. The anchors are preferably spaced at equal circumferential positions. The windings are a progressive windings, with various sections, and each section has a number of layers. Each progressive section is anchored by at least two of the anchors. The first and second windings are wound directly on the core insulation, and the insulating jacket is mounted directly on the core.

Abstract: The apparatus for cooling a high power electrical transformer and electrical motors uses thermally conductive material interleaved between the turn layers of a high power transformer and iron core laminates to provide a low resistant thermal path to ambient. The strips direct excess heat from within the interior to protrusions outside of the windings (and core) where forced air or thermally conductive potting compound extracts the heat. This technique provides for a significant reduction of weight and volume along with a substantial increase in the power density while operating at a modest elevated temperature above ambient.

Abstract: A high-leakage planar magnetic component such as an inductor, having a winding structure in which flat winding turns are oriented transverse to the plane of the winding structure, exhibits significantly lower winding losses than components having a stacked arrangement of flat winding turns parallel to the plane of the winding structure. A dense winding structure having such a transverse orientation can readily be made by forming a flat conductor into a coil using conventional wire winding techniques.

Abstract: A stick-type ignition coil have a central core, a cylindrical member, primary spool, primary coil, secondary spool, secondary coil, outer core and a resin insulator. The two longitudinal end corners and faces of the core are covered by respective buffer members. The inner circumferential corners of the outer core is supported by ring members. Some of the members disposed radially inside and other members disposed radially outside of the inside members are held slidably to each other in the ignition coil. The spools are made of resin containing a rubber in excess of 5 weight percent and reinforcing materials. The resin insulator contains a flexible material.

Abstract: A transformer comprises a printed circuit board having elongated conductors printed thereon, a ferrite core having a bottom mounted onto the printed circuit board and a flex circuit. The flex circuit comprises a dielectric sheet and elongated conductors printed on both faces of the sheet. The flex circuit is contoured around a top and sides of the core. The conductors of the flex circuit are surface bonded to respective conductors of the printed circuit board to form a series of primary windings and a series of secondary windings around the core. Provision of the upper portions of the windings by means of the flex circuit is economical because it does not require handling of discrete conductor portions.

Abstract: A dry-type transformer having an iron core, with high voltage and low voltage coils encapsulated in casting resin. The high and low voltage windings may be cast separately, or together. Either or both of the coils may have integral axial cooling channels, as may the annular axial space between the inner and outer windings (usually low voltage and high voltage, respectively). Coil cross-section is a modified oval (Rectoval.TM.) shape, in that the sides of the coil are substantially linear and the ends of the coils are substantially semi-circular. The aspect ratio (L/W) of the coil, when viewed in radial cross-section, ranges from greater than 1.0 to about 2.5. The rectangular nature of the coil allows for the use of a core member having a rectangular cross-section, thereby reducing the manufacturing expense involved with shaping the core member. The circular nature of the ends of the coil provide improved strength similar to that of circular/cylindrical coils.

Abstract: An improved low voltage winding for dry insulated transformer has its windings resin encapsulated. The winding is constructed with flexible sheet conductors wound coincident with an insulating sheet material. Insulating spacers provide a means to form air channels in the windings during the coil forming process. A sealant is applied to openings at the lower ends and along vertical seams of the coil prior to the resin impregnation and encapsulation process. This will prevent drainage of the resin during a curing cycle. The result is a coil that exhibits high short circuit protection due to the tightly bond sheet conductors which will prevent movement of the conductors during short circuit conditions and also increases the radial compressive strength of the coil.

Abstract: An inductance device wherein a conductor film is formed on a base, grooves are formed in the conductor film, a protective material is disposed on the grooves, and a length L1, a width L2 and a height L3 of the inductance device satisfy-the following relation:L1=0.5 to 1.5 mm;L2=0.2 to 0.7 mm; andL3=0.2 to 0.7 mm.

Abstract: A low-profile transformer or inductor includes a leg of a magnetically permeable core. A tube-type winding arrangement is made by use of a flat, flexible dielectric sheet, on one side of which a broad conductive area is affixed, and on the other side of which a plurality of mutually parallel elongated regions are affixed. The dielectric sheet is rolled into a tube defining a parting line which is perpendicular to the axes of elongation of the conductive strips. The discontinuous elongated strips are formed into a continuous winding by means of stitches. The stitches may be through vias extending through overlapping regions of the tube to interconnect ends of the strip conductors, or may be generated by an HDI conductor overlying the ends of the strip conductors, with through vias making connections to the ends of the strip conductors and to HDI conductors.

Abstract: An improved transformer coil of the type characterized as a shell-form or pancake coil used in large scale power transmission transformers. The improvement adds strength to resist lateral edge coil deformation as a result of handling the coil during transformer assembly and as a result of fault current surges. The improvement is directed to tightly spread taping some of the inner and outermost conductor turns together with preferably a heat shrinkable structural tape. This spread taping is periodic or spaced along the outer periphery of the coil for economy and may be staggered in terms of the number of conductor turns wrapped together. Preferably, the innermost conductor turns may also be spread taped in this same manner.

Abstract: A miniature electromagnetic relay is capable of increasing the coil packing density, yet assuring electrical insulation of the coil from a core of the electromagnet. The relay includes a pair of movable and fixed contacts, an armature carrying the movable contact, and an electromagnet block having an excitation coil which moves the armature for closing and opening the contacts upon being energized. The electromagnet block includes a generally U-shaped core with a center core and a pair of yokes extending from opposite ends of the center core, flanges of dielectric material molded respectively around portions of the yokes, and a dielectric tape fitted around the center core over substantially the entire length of the center core to receive therearound the excitation coil in an electrically insulating relation from the core.

Abstract: There is disclosed a high voltage transformer for a television receiver, comprising a coil former in which there are situated auxiliary windings, a primary winding over the auxiliary windings, and a high voltage winding over the primary winding. A first sleeve forms a flat base for the primary winding, and is arranged on the auxiliary windings. The primary winding is wound from a plurality of layers of solid wire, each layer disposed directly over the other, and a further sleeve made of a dielectric inserted between two of the plurality of layers.

Abstract: An inductance device wherein a conductor film is formed on a base, grooves are formed in the conductor film, a protective material is disposed on the grooves, and a length L1, a width L2 and a height L3 of the inductance device satisfy the following relation:L1=0.5 to 1.5 mm;L2=0.2 to 0.7 mm; andL3=0.2 to 0.7 mm.

Abstract: A transformer has a bobbin having a winding surface formed at a periphery thereof. Provided on the winding surface of the bobbin are at least one primary winding layer formed by a conductor wound around the winding surface of the bobbin, at least one secondary winding layer formed by a conductor wound around the winding surface of the bobbin, and at least one insulating layer each arranged between an associated one of the at least one primary winding layer and an associated one of the at least one secondary winding layer, for insulating them from each other. The at least one insulating layer is bent at an associated one of the at least one end portion of the bobbin and extends from the winding surface of the bobbin to a portion of the bobbin other than the winding surface.

Abstract: A solenoid coil formed by winding a conductive foil tape upon a sleeve and method for making same. The coil includes a free standing wire termination which is wound into the coil. Alternately, the end of the foil tape can be folded to form a coil termination.