Abstract: A lightweight inductor for the motor controller of an aircraft starter includes a toroidal inductor core divided into multiple sections that are separated by a thermally conductive, but electrically insulating, material. The inductor core is wound with wire and positioned inside of an electrically and thermally conductive container, which acts as a heat sink and EMI shield, while also reducing eddy currents within the inductor core.

Abstract: An electrically insulating bobbin surrounds the magnetic core of an inductor. The bobbin includes a number of channels to receive wire for making an inductor. When wire is positioned in the channels, the wire is wound around the inductor core, but insulated from the inductor core and the other turns of wire. Because the bobbin insulates the turns of wire from each other and from the inductor core, bare rope wire can be used to wrap the inductor, resulting in reduced size and weight and improved ease of manufacture.

Abstract: An electrical inductor assembly comprises an inductor core having a circular shape, a wire guide that surrounds the inductor core and includes a plurality of slots, at least one of the slots forming a path winding around the inductor core, and at least one wire placed in one of the plurality of slots to form a winding. A method of forming an electrical inductor assembly comprises forming an inductor core having a circular shape, surrounding the inductor core with a wire guide, winding at least one wire around the inductor core along a slot in the wire guide, and applying an insulating material to the slot containing the at least one wire to electrically insulate the at least one wire.

Abstract: Three single-phase interphase transformers are connected to a three-phase transformer. The three single-phase interphase transformers each contain a component for efficiently dissipating heat.

Abstract: A lightweight inductor for the motor controller of an aircraft starter includes a toroidal inductor core divided into multiple sections that are separated by a thermally conductive, but electrically insulating, material. The inductor core is wound with wire and positioned inside of an electrically and thermally conductive container, which acts as a heat sink and EMI shield, while also reducing eddy currents within the inductor core.

Abstract: An electrically insulating bobbin surrounds the magnetic core of an inductor. The bobbin includes a number of channels to receive wire for making an inductor. When wire is positioned in the channels, the wire is wound around the inductor core, but insulated from the inductor core and the other turns of wire. Because the bobbin insulates the turns of wire from each other and from the inductor core, bare rope wire can be used to wrap the inductor, resulting in reduced size and weight and improved ease of manufacture.

Abstract: An electrical inductor assembly comprises an inductor core having a circular shape, a wire guide that surrounds the inductor core and includes a plurality of slots, at least one of the slots forming a path winding around the inductor core, and at least one wire placed in one of the plurality of slots to form a winding. A method of forming an electrical inductor assembly comprises forming an inductor core having a circular shape, surrounding the inductor core with a wire guide, winding at least one wire around the inductor core along a slot in the wire guide, and applying an insulating material to the slot containing the at least one wire to electrically insulate the at least one wire.

Abstract: An electrical inductor has at least one wire wound core. When the wire wound core is placed within the shell at least one cavity is present. This cavity is filled with a powder to provide the inductor with better thermal and electrical properties.