Abstract: A transformer includes a ferrite base plate having a chamber for receiving a winding and one or more further windings which may be coupled to a ground. The windings are electrically coupled together, and separated from each other by partitions. An insulating strap may be wound around the ferrite base plate, and engaged with the ground, for securing the ground to the ferrite base plate and for preventing the ground to the ferrite base plate from moving relative to the ferrite base plate. One or more conductive panels may be engaged between the partitions of the windings.

Abstract: The present invention provides for a grounded circulator that is isolated from the environment. Thus, the circulator of the present invention allows circuit board manufacturers to wash the finished, or partially finished, circuit board after the present invention has been attached to the circuit board without damaging the circulators. The present invention does this by incorporating a novel means for grounding the ferrites of the circulator using a grounding foil wrap so that traditional methods for grounding the ferrites which necessitate that the circulator be unsealed, such as screws and use of the circulator cover, are not used. The present invention also provides for communication by the circulator with other electronic components without compromising the isolation of the interior of the circulator through the use of embedded microstrips.

Abstract: A side-by-side coil inductor includes a first coil comprising a plurality of conductive first coil segments positioned one above another and connected in series. A second coil includes a plurality of conductive second coil segments positioned above one another and connected together in series. The first and second coil are in side-by-side position relative to one another and are connected together in series. Each of the first and second coil are approximately circular or square in configuration and the total configuration of the two coils is rectangular.

Abstract: A low profile surface mountable toroid inductor. The apparatus features a one step molded housing which includes a cover and opposing mounting legs. The housing is molded in a liquid crystal polymer. The length of wire that provides the turns on the toroid also serves as the mounting pads as each end of the wire that is left exposed during the housing molding process is then wrapped around its corresponding leg to provide a mounting pad. The apparatus is able to achieve a thickness that is less or equal to 1.5 mm by eliminating the thickness of a prefabricated cover. Further, a flat surface can be molding into the housing so that the apparatus can be positioned with “pick and place” techniques. Also, the apparatus can be configured so that it can be mounted upside down as well.

Abstract: A surface-mount air-core coil has a coil body formed by winding a conductive wire spirally and mount legs formed by folding both ends of the conductive wire horizontally toward the inside. The lower surfaces of the mount legs are positioned below the lower surface of the coil body. The length of the mount legs is set longer than the width of the coil body.

Abstract: The invention relates to a transformer tank generally shaped like a rectangular prism and filled with insulating liquid and assembled mainly by welding. The tank comprises a detachably fastened transformer cover plate and a transformer core placed in the transformer tank while the cover plate is detached. In accordance with the invention, at least one of the substantially vertical walls of the transformer tank comprises a detachable wall portion whose detachment allows the transformer core to be removed from the transformer tank through an opening formed by the detachment of the wall portion. In this way the transformer can be repaired on site without having to lift the transformer core from the transformer tank in the conventional manner, which would require free space above the transformer.

Abstract: A power supply transformer for telephone to be incorporated in an AC adapter as a power supply for a telephone. A bobbin used in a power supply transformer for a telephone is configured by taking insulation as well as an insulation distance into consideration and is partitioned into three winding frames with a plurality of flanges to configure. A primary side input coil, which is connected with a power supply for commercial use, is coiled at the coil portion of the bobbin, a secondary side output coil is coiled for charging at another coil portion, and a secondary side output coil is coiled for a telephone line at still another coil portion are deemed to serve for improvement in insulation and reservation of insulation distance mutually between the respective coils.

Abstract: The transformer bobbin of the present invention includes a tubular body, a first partition wall, at least one second partition wall, at least one third partition wall and pins. The first partition wall is formed on the surface of the tubular body. The first partition wall includes a first flange having a thinner section for providing winding of a wire. The first partition wall separates a primary side from a secondary side. The second partition wall, parallel to the first partition wall, is formed on the surface of the tubular body. The second partition wall includes a second breach and a second flange having a second cut corner formed thereon. The third partition wall, interposed between the adjacent second partition walls, includes a third breach and a third flange having a third cut corner formed thereon. There is a horizontal height difference exists between the second cut corner and the third cut corner.

Abstract: A method for producing electronic components having a plurality of electrically conductive windings that includes the steps of connecting a plurality of segments of electrically conductive material to a container to form a plurality of half-turns, and mounting the combination of the container and the half-turns on a mounting structure having a plurality of electrically conductive tracks by connecting the half-turns to the plurality of electrically conductive tracks. In alternative embodiments, the segments are formed into half-turns and then connected to a container or a support structure. The resulting combination of the half-turns and electrically conductive tracks forms the plurality of conductive windings. The method may be used to produce coils, inductors, and transformers.

Abstract: An electric noise absorber for preventing looseness of magnetic body parts in a closed housing, without increasing the number of parts or decreasing the strength of the housing. The housing comprises a pair of case halves which house ferrite core halves, respectively, and are hinged to each other. The bottom wall of each case half is formed with a curved shape convex toward the space housing the ferrite core half. When the case halves are closed with the ferrite cores therein, the ferrite cores press each other toward respective bottom walls and resiliently deform the walls. The resilience of the deformed bottom walls urges abutting surfaces of the ferrite cores into close contact.

Abstract: A three-dimensional micro-coil situated in a planar substrate. Two wafers have metal strips formed in them, and the wafers are bonded together. The metal strips are connected in such a fashion to form a coil and are encompassed within the wafers. Also, metal sheets are formed on the facing surfaces of the wafers to result in a capacitor. The coil may be a single or multi-turn configuration. It also may have a toroidal design with a core volume created by etching a trench in one of the wafers before the metal strips for the coil are formed on the wafer. The capacitor can be interconnected with the coil to form a resonant circuit An external circuit for impedance measurement, among other things, and a processor may be connected to the micro-coil chip.

Abstract: A support is used to modify an inductive device to a surface mounting device. The inductive device is provided with a core and a coil, and the support includes an electric portion and an isolation portion. The electric portion, having a first surface and a second surface opposite to the first surface, is electrically coupled to the coil. The first surface of the electric portion is in contact with the core. The isolation portion is disposed on the second surface of the electric portion in a manner such that the isolation portion covers one part of the second surface of the electric portion. The isolation portion is flush with the other part of the second surface of the electric portion.

Abstract: One or more heat-conducting devices are located coincident with a bobbin that is used to form the coils of the transformer. The coil wire is subsequently wrapped around the bobbin and adjacent heat-conducting device assembly, using conventional coil winding techniques. The heat-conducting device is preferably configured to extend beyond the transformer so as to contact a heat-conducting surface, such as a ballast enclosure, when the transformer is appropriately mounted. Because the heat-conducting device is located adjacent the inner windings of the coil, which is typically the locale of the highest temperature build-up in a transformer, a highly efficient heat-transfer is achieved. Preferably, the heat-conducting device comprises one or more copper conductors, with a thin layer of insulating tape separating the copper conductors from the coil windings.

Abstract: There is disclosed a coil device, which has a coil composed of a core and a winding on the core, and a terminal having a base seat for holding the coil and terminal elements. The coil device has a flange on one side of the core with no flange being provided on the other side of the core. This allows molding by using a mold and can reduce a thickness of the flange of the core and realize reduction of thickness of the coil device.

Abstract: A hook constituted by a guide groove formed in a substantially center of a lower surface is provided in a lower portion of a first projection (22), a terminal end (13a) of a coil (13) is bent along both right and left side surfaces and a lower surface of the first projection (22), and the terminal end (13a) is fitted and inserted to the guide groove at this time, whereby a terminal end treatment of the coil (13) is performed. Further, second projections (24) having a horizontal cross section formed in a rectangular shape are integrally formed in a center left end of a left flange (21) and a center right end of a right flange (21), an inclined surface (24a) is formed downward on right side surfaces of both of the second projections (24), and the inclined surface (24a) slides an inner peripheral edge of a second through hole at a time of inserting the second projection (24) to a second through hole in a printed circuit board side.

Abstract: A transformer apparatus comprises a core member including a base portion, a center core portion and at least three side core portions fixed on peripheral parts to stand thereon. The transformer apparatus further comprises a primary coil fitted around the center core portion; a first plate coil member in a frame-like shape enclosing the outside of the side core portions; a second plate core member in a frame-like shape enclosing the outside of the side core portions and being combined with the first plate coil member in a laminated state having an insulating layer therebetween. The transformer apparatus further comprises connecting coil pieces cantilevered by each side portion of the second plate coil member correspondingly to the side core portions. Each free end of the connecting coil pieces extends to enclose the outer periphery portion of a corresponding side core portion to be connected with the first plate coil member.

Abstract: A DC to DC converter having a flange attached to the housing. The flange configured to electrically isolate, insulate and shield the DC to DC converter from an underlying circuit board. The flange may be further configured to meet creepage distances and air clearances required by various regulatory and certification agencies.

Abstract: A surface-mount air-core coil has a coil body formed by winding a conductive wire spirally and mount legs formed by folding both ends of the conductive wire horizontally toward the inside. The lower surfaces of the mount legs are positioned below the lower surface of the coil body. The length of the mount legs is set longer than the width of the coil body.

Abstract: A mounting apparatus for an electromagnetic device such as a transformer of inductor includes a generally planar metallic plate as a first heat sink, and a metallic mounting cup as a second heat sink. The mounting cup includes a cavity configured to receive the electromagnetic device, the cavity being defined by a base, and an axially-extending annular sidewall extending from the base to a flange portion of the mounting cup. The mounting cup includes first and second passages for allowing the leads of first and second windings of the electromagnetic device to be routed out of the cavity. The cavity is filled with a polyurethane potting resin, and the mounting cup, including the potted electromagnetic device, is mounted to the plate heat sink using fasteners. The mounting cup, which surrounds the electromagnetic device, in combination with the potting resin provides improved thermal transfer to the plate heat sink, as well as providing resistance to vibration and shocks.

Abstract: The invention relates to a transformer tank generally shaped like a rectangular prism and filled with insulating liquid and assembled mainly by welding. The tank comprises a detachably fastened transformer cover plate and a transformer core placed in the transformer tank while the cover plate is detached. In accordance with the invention, at least one of the substantially vertical walls of the transformer tank comprises a detachable wall portion whose detachment allows the transformer core to be removed from the transformer tank through an opening formed by the detachment of the wall portion. In this way the transformer can be repaired on site without having to lift the transformer core from the transformer tank in the conventional manner, which would require free space above the transformer.

Abstract: A bead inductor has excellent productivity and increased reliability in the connection between an internal conductor and external terminals. A method for manufacturing such a bead inductor includes the steps of forming an internal conductor and the external terminals as an integral, unitary member such that the external terminals are disposed at both ends of the internal conductor and electrically connected thereto; positioning the integral, unitary member in a metallic mold; and molding a resin material or a rubber material including a powdered magnetic substance in the metallic mold so as to embed the internal conductor therein.

Abstract: A common mode filter includes a drum-shaped core 1 with a winding 2 and a plate-like core fixed to flanges 1b to form a closed magnetic path. Concave portions 4a are formed in at least one of facing potions of both cores to provide gaps between the flanges 1b of the drum-shaped core and the plate-like core 4. A plurality of electrodes 3 each of which is successive over a upper surface, end face and lower surface of each flange are provided at portions corresponding to the gaps in each flange 1b. A plurality of windings 2 are wound around the winding core 1a so that both ends of each of the plurality of windings are electrically connected and secured to the portions of the electrodes on the upper surface of each of the flanges, respectively, by conductive fixing agent. The drum-shaped core 1 and the plate-like core 4 are fixed to each other by an adhesive 5.

Abstract: The invention relates to a mid-frequency high power transformer which is specially used as a welding transformer in resistance welding, comprising a primary winding penetrated by the limb of a transformer core and a secondary winding which are configured as concentrically overlapping cylindrical windings. The windings of the primary windings are formed by a plurality of spirally wound layers of a relatively thin electrically conductive metal strip material, and the windings of the secondary winding are formed by an appropriate number of spirally wound layers of a thicker electrically conductive metal strip material chosen according to the desired reduction ratio between the primary and the secondary windings.

Abstract: An electrically conductive wire wound into a conical coil 1 with leads from the small and large ends of the coil. The coil is filled with fine-grained magnetic material 11, and is mounted in a thin-walled, electrically non-conductive carrier 21 designed for precise automated assembly onto a circuit board 15. The wire leads are plastic-welded onto the carrier, and no metallic pads are used, greatly increasing the effective bandwidth of the choke. The small end 4 of the coil is positioned precisely on a micro-strip 17 on the circuit board. Attachment of the wire lead from the small end of the coil to the microstrip is done with minimum lead length and minimum conductive material for the highest possible frequency response. Precise coil positioning, minimal lead length, and a totally non-conductive carrier virtually eliminates electrical reflections and resonances to yield a broadband choke with exceptional frequency range.

Abstract: A packing structure of an electronic device by interconnecting a frame and frame leads with an insulating block is provided. The packing structure has the advantage of measuring the electrical characteristics of the semi-product before being subject to a plastic molding. The packing structure includes a frame having a package area where an electronic device is disposed, an insulating block disposed on one side of the package area and connected to the frame, and a plurality of frame leads aligned in parallel and connected to the insulating block and the electronic device.

Abstract: A spiral inductor fabricated above a semiconductor substrate provides a large inductance while occupying only a small surface area. Including a layer of magnetic material above and below the inductor increases the inductance of the inductor. The magnetic material also acts as barrier that confines electronic noise generated in the spiral inductor to the area occupied by the spiral inductor. Inductance in a pair of stacked spiral inductors is increased by including a layer of magnetic material between the stacked spiral inductors.

Abstract: A holder for containing a split ferrite suppressor includes two halves hinged to each other along one side, each half including a recess adapted to hold one portion of a split ferrite suppressor. Each half of the holder also includes two ends, each end containing a generally semicircular notch adapted to receive a cable to which the suppressor is to be applied, and locking tabs disposed on both sides of the semicircular notch for locking the two halves of the holder together. The locking tabs are preferably arranged as confronting mating pairs of male and female elements, each element having a head portion and a neck portion smaller than the head portion. The interlocking tabs preferably include tapering surfaces connecting the head and neck portions, the tapering surfaces applying a biasing force tending to hold the two halves of the holder together. The tapering surfaces are preferably substantially planar surfaces inclined at about 10° with respect to a line bifurcating said head and neck portions.

Abstract: A surface mount core assembly comprises a header with breakaway support rails. The breakaway support rails are used in the manufacturing process to maximize the core window of the assembly, and may be removed to minimize the footprint of the assembly. In the present embodiment, the assembly comprises, for example, a transformer wherein prefabricated conductor rings are used to further maximize the fill of the core window with conductor material.

Abstract: The present invention provides a low-voltage bobbin of a flyback transformer. The flyback transformer comprises the low-voltage bobbin, a lower core and an upper core. The low-voltage bobbin comprises a main body and a reinforced device. The main body comprises a skirt and a winding shaft. The skirt has a lower opening for receiving the lower core. A plurality of sockets are provided on a side portion of the skirt. The winding shaft is provided on the skirt and has an upper opening for receiving the upper core. The reinforced device is provided on the skirt for reinforcing rigidity of the main body and preventing the plurality of sockets from displacing. In addition, the reinforced device comprises three ribs integrally formed on a flange of the skirt. Each rib is vertically connected with each other to form a hole. The lower core engages with the low-voltage bobbin through the hole according to a predetermined assembly procedure.

Abstract: A fluid cooled electric conductor for induction heating of a workpiece includes a flexible conductor which is enclosed within an insulating tube. The conductor is supported within the tube so as to be surrounded by a fluid conducting space or spaces. A support arrangement supports the tube. Temperature sensors adjust the heating process by, for example, operating variable-length holders that support the tube in a spaced relationship with a workpiece.

Abstract: An electronic surface mount package provides a one piece construction package (with an open bottom) with one or more terminal pins molded into the package. Each of the pins have a notched post upon which a wire is wound which is from a toroid transformer carried within the package. Each of the posts are notched so their respective wires are separate from one another so as to prevent arcing. The case is opened at the bottom which prevents harm from expansion or cracking. A reinforcement beam is located laterally across the bottom of the package to provide mechanical strength for the case.

Abstract: Disclosed is a transformer bobbin with hipot-protect structure. The bobbin is integrally formed from plastic material through injection molding and includes a central shaft portion and an outer frame portion at two ends of the central shaft portion. When the bobbin is formed during molding, the outer frame portion is extended from one or two lateral outer ends thereof for a length and therefore forms one or two extended portions on the bobbin. Upright rib or ribs may be additionally provided on top surface of the extended portion. The extended portion provide increased creepage distance between pins connected to outer end surfaces of the bobbin and the core of the transformer to effectively prevent hipot from transiting from pins at one end to pins at the other end by crossing over the core directly.

Abstract: A surface mount, tunable inductor (200) includes a core (205) that is substantially toroidal in shape. The core (205) has a first flattened surface (206) and a second flattened surface (207) opposite the first flattened surface (206), and a hole (208) is formed through the core (205). A wire (210) is wound about the core (205) and terminates in first and second leads (215). The inductor (200) also includes a substrate (220) on which first and second conductive pads (225) are formed. Each of the wire leads (215) is electrically coupled to one of the conductive pads (225), and an adhesive (240) secures the first flattened surface (207) of the core (205) to the substrate (220).

Abstract: A surface-mountable magnetic device comprising: (1) a multi-layer circuit containing a plurality of windings disposed in layers thereof, the multi-layer circuit having first and second lateral recesses associated therewith, the first and second lateral recesses intersecting the layers of the multi-layer circuit, (2) a conductive substance disposed within the first and second lateral recesses and electrically coupling selected ones of the plurality of windings and (3) a magnetic core mounted proximate the plurality of windings, the magnetic core adapted to impart a desired magnetic property to the plurality of windings, the device locatable proximate a substantially planar substrate to allow the first and second lateral recesses to act as conductors between the plurality of windings and electrical conductors on the substantially planar substrate, the plurality of windings and the magnetic core substantially free of a surrounding molding material to allow the magnetic device to assume a smaller overall device v

Abstract: A fly back transformer includes a main body, a collecting element and a wire. The collecting element is fixed to the main body, while the wire is connected to the main body via the collecting element. The collecting element or the main body has a fixing portion. The wire is fixed to the collecting element or the main body by the fixing portion to prevent a separation between the wire and the collecting element.

Abstract: A driving unit of a cross-coil type indicating instrument includes a bobbin and a pair of cross-coils crossing each other, a plurality of terminals having an edge portion, a bent portion, and a rod portion. The edge portion is bent at the bent portion to extend toward the cross-coils, and each of the pair of cross coils has a wire end wound around a spool portion formed in the edge portion and soldered thereto. Each of the male terminals has a dam for holding melting solder between the spool portion and the bent portion.

Abstract: A plate-like coil formed by a metal plate is buried in a base made from an insulating material in a state in which electrode terminals and a fixing terminal of the plate-like coil are projecting from the base. The base has through-holes in which a central leg and side legs of an E-shaped core are to be inserted. The E-shaped core and an I-shaped core are mounted to the base while holding the base therebetween, and the electrode terminals and the fixing terminal projecting from the base are bent to the bottom surface of the base.

Abstract: An inductive device includes a magnetic core, a conductive winding surrounding the core, a conductive element formed on a selected portion of the surface of the magnetic core, and a termination of the winding mechanically attached and electrically connected to the conductive element. In an assembly that includes a circuit board the conductive element is mechanically attached and electrically connected to a connection pad on the board and the winding termination is connected to the conductive element.

Abstract: A thin electrically conductive wire wound into a conical coil 1 with leads from the small and large ends of the coil. The coil is filled with powdered iron 11, and is mounted in a thin-walled, completely non-conductive, leadless carrier 21 for ease of assembly onto a circuit board 15. The small end 4 of the coil is positioned precisely on a micro-strip 17 on the circuit board to provide maximum bandwidth. The coil is held by the carrier at an angle such that the large end of the coil is displaced from the circuit board by a distance D of at least half the radius of the large end of the coil. Attachment of the leads from the small and large ends of the coil to respective contacts on the circuit board is done with minimum lead length, minimum conductive material, and without the use of metallic pads on the carrier, to yield the highest possible frequency response.

Abstract: A universal transformer tank for distribution transformers is comprised of a cylindrical housing having a circumferential side wall, a bottom wall and an open top end. A cover is removably secured on the open top end. An adjustable clamping assembly is secured inside the housing above the bottom wall and has adjustable clamping means to secure distribution transformers of varying configurations capacities and size inside the housing.

Abstract: A transformer tank with detachable cabinet interface. The transformer tank has a metal front panel for attachment of an electrical cable. A one-piece enclosure of non-conductive, flame resistant material cooperates with the front panel to provide an enclosed cable compartment for the transformer tank. A cabinet interface of non-conductive, flame resistant material is mounted on the periphery of the front panel. The interface is comprised of strip material having a tongue and groove or Y-shape.

Abstract: To produce a coil device in which fewer components are required, a plurality of coils 20 are attached to an attachment base 10, leading wires 24 of each coil 20 being attached to terminal fittings 30A and 30B of a connector member 13, and a feeder connector C being fitted with the connector member 13. Electricity is distributed to each coil 20 along a path of feeder electric wires W, the feeder connector C, the connector member 13, and leading wires 24. The leading wires 24 of the plurality of coils 20 are attached as a single unit to the single connector member 13. Since the feeder connector C is attached to this connector member 13, fewer components are required compared to the case in which each coil 20 is provided with an individual connector member.

Abstract: A surface-mount air-core coil has a coil body formed by winding a conductive wire spirally and mount legs formed by folding both ends of the conductive wire horizontally toward the inside. The lower surfaces of the mount legs are positioned below the lower surface of the coil body. The length of the mount legs is set longer than the width of the coil body.

Abstract: An integrated inductive assembly includes first and second inductive elements each comprising a winding wherein winding axes of the windings are perpendicular to one another. In addition, the first and second inductive elements are carried adjacent one another by a bracket.

Abstract: A noise absorbing apparatus includes a noise absorbing unit and a fixing base. The noise absorbing unit is constituted by a pair of ferrite members and a pair of covers covering the ferrite members. The ferrite members are positioned to oppose each other to be in tight contact with each other to sandwich a cable. The fixing base is fixed on a chassis where the cable extends, and fits on the noise absorbing unit, thereby fixing the noise absorbing unit on the chassis.

Abstract: An inductive component including a primary coil having first and second terminals, and a secondary coil including a coil substrate, wiring patterns, and conductive terminals. The coil substrate is provided with alignment recesses for receiving and locating the first and second terminals of the primary coil in a fixed relationship to each other and to the conductive terminals of the secondary coil and an inductive component assembly having the inductive component is mounted outside a periphery of a substrate. A magnetic core of the inductive component has a central portion which is displaced off an edge of the magnetic core and has bevelled edges at a base of the central portion of the magnetic core. Terminals of both the primary coil and the secondary coil are located close together on the same side of the inductive component to reduce thermal stress.

Abstract: A housing for a toroid coil has side walls closely formed around the coil and a top connected at a gap from the side walls by attachments. The top provides a flat, relatively smooth vacuum pick up surface for mounting the coil on a circuit board and is removable by breaking off the attachments. The side walls have a front wall with wire wrap posts extending therefrom positioned so that the wire of the coil lies in the mounting plane for surface mount connection when wrapped on the posts. Slots are provided in the front wall to receive the wire to prevent cutting or scoring of the wire or its coating or cover during removal of the top. The back of the walls is open to reduce length and thickened supports are provided at the edges of the walls adjacent the back.

Abstract: An isolating cover for mounting on a top of a bobbin of a small-scaled transformer to cover windings and pins provided on the bobbin and isolate them from a frame core of the transformer. The isolating cover is so designed that it has isolating walls to provide increased creepage distances between any two components on the transformer and therefore prevents a hipot from directly crossing from a high-tension end to a low-tension end on the transformer. The increased creepage distances at all areas of the bobbin enable upgraded quality and reliability of the transformer. The isolating cover can be easily mounted to the bobbin to replace conventional insulating tape for covering the top of the bobbin, and has dimensions that do not exceed an overall volume defined by the bobbin. The transformer with the isolating cover can therefore be manufactured with simplified procedures and at reduced cost.

Abstract: The invention relates to a planar transformer arrangement for an electric circuit located on a circuit board. The arrangement comprises (a) a first circuit board (PCB1) on which said electric circuit has been implemented, (b) a supplementary circuit board piece (PCB2), (c) a primary winding which comprises at least one substantially planar conductive pattern formed on a circuit board, (d) a secondary winding which comprises at least one substantially planar conductive pattern formed on a circuit board, and (e) a transformer core (F1, F2) which surrounds the primary and secondary windings at least partially. To create an inexpensive but efficient transformer structure suitable for use in an automatic manufacturing process, both the primary and the secondary windings have been formed on the supplementary circuit board piece (PCB2).

Abstract: A transformer is provided that consists of a primary winding, a secondary winding and a magnetic core. The primary winding is wound directly around the magnetic core, thereby removing the need for a bobbin. By removing the need for the bobbin, the transformer has a large window utilization factor, and associated low profile. As a result, the transformer has a high power to form factor ratio. A method for making the transformer includes the steps of joining two halves of the core before winding the primary winding. Because the half-cores are joined prior to the wrapping of the primary winding, the core provides bobbin functionality. In addition, a header plate is provided for coupling a plurality of leads of a transformer to sources on an integrated circuit board, where the transformer consists of a magnetic core, a primary winding and a secondary winding. The header plate engages the magnetic core, providing a termination path for the wire of the secondary winding.