Abstract: Embodiments of an electromagnetic coil assembly are provided, as are methods for the manufacture of an electromagnetic coil assembly. In one embodiment, the method for manufacturing an electromagnetic coil assembly includes the steps of providing a braided aluminum lead wire having a first end portion and a second end portion, brazing the first end portion of the braided aluminum lead wire to a first electrically-conductive interconnect member, and winding a magnet wire into an electromagnetic coil. The second end portion of the braided aluminum lead wire is joined to the magnet wire after the step of brazing.

Abstract: A method for making a magnetic component is provided. The method comprises providing a core with one or more ridges protruding from one or more surfaces of the core, depositing one or more electrically conductive materials on the core, and removing at least a portion of the one or more ridges to form one or more continuous conductors wound around the core. Each of the one or more continuous conductors defines at least one insulating gap. Further, a magnetic component and methods for making the magnetic component are also presented.

Abstract: In accordance with an embodiment, an implantable lead assembly is provided comprised of an elongated body including a distal end, a proximal end having a header connector portion for coupling the elongated body with an implantable medical device, and an intermediate segment located between the distal and proximal ends. An intermediate electrode is disposed at the intermediate segment along the elongated body. A conductor is disposed in the elongated body and electrically coupled with the header connector portion and the intermediate electrode. The conductor wound within the intermediate segment to form first and second inductive coils that are axially separated from each other by an inter-coil gap, wherein the first and second inductive coils have different self-resonant frequencies.

Abstract: An integrated circuit has a semiconductor die provided in a first IC layer and an inductor fabricated on a second IC layer. The inductor may have a winding and a magnetic core, which are oriented to conduct magnetic flux in a direction parallel to a surface of a semiconductor die. The semiconductor die may have active circuit components fabricated in a first layer of the die, provided under the inductor layer. The integrated circuit may include a flux conductor provided on a side of the die opposite the first layer. PCB connections to active elements on the semiconductor die may progress through the inductor layer as necessary.

Abstract: Disclosed herein is a method for manufacturing an inductor, including: forming a coil laminate by inserting spiral coils into a guide shaft disposed at a center of a magnetic substrate; providing a molding part so as to surround the coil laminate; removing the guide shaft; and providing a ferrite composite so as to surround the molding part.

Abstract: [Problem to be solved] A first coil and a second coil are efficiently formed in the shape of a rectangular cylinder and in parallel to each other, by bending and processing a flat wire, and a linking part of each of the coils, is linked with the same material without welding or folding.

Abstract: A surgical navigation system for navigating a region of a patient includes a non-invasive dynamic reference frame and/or fiducial marker, sensor tipped instruments, and isolator circuits. The dynamic reference frame may be repeatably placed on the patient in a precise location for guiding the instruments. The instruments may be precisely guided by positioning sensors near moveable portions of the instruments. Electrical sources may be electrically isolated from the patient.

Abstract: Ceramic inductors are made from stacked sheets of co-fired ceramic. At least one of the ceramic sheets has a slot with a conductor disposed in the slot. The conductor has a thickness equal to a thickness of the ceramic sheet containing the slot. The conductor has a large thickness (compared to prior art co-fired ceramic inductors) and therefore can carry large currents. The present ceramic inductor can be used in power electronics applications due to the ability to carry large currents. The present ceramic inductor preferably has an inductance that decreases with increasing current. A decreasing inductance characteristic tends to increase energy efficiency in a voltage regulator when the inductor is used as an output inductor. Specifically, the variable inductance tends to substantially increase energy efficiency at low current loads without adversely affecting efficiency at high loads.

Abstract: A method of producing a surface-mount inductor having an external electrode with high connection reliability even in a high-humidity environment is provided. The method comprises the steps of: forming a coil by winding an electrically-conductive wire having a self-bonding coating; forming a core portion using a sealant comprising metal magnetic powders and a resin so as to encapsulate the coil while allowing each of opposite ends of the coil to be at least partially exposed on a surface of the core portion; applying an electrically-conductive paste containing metal fine particles having a sintering temperature of 250° C. or less onto the surface of the core portion; and forming an underlying electrode on the surface of the core portion by sintering the metal fine particles through a heat treatment of the core portion to achieve electrical conduction with the coil.

Abstract: Coating an elongate, uncoated conductive element with a barrier layer to form an insulated conductive element. The insulated conductive element comprises substantially continuously coated elongate sections separated by uncoated gaps which are substantially small relative to the lengths of the coated sections.

Abstract: First and second divisional cores each including right and left leg portions and a yoke interconnecting those together are formed by molding respective yoke-side core members in a resin. Cylindrical core mounting portions extending from the outer circumference of the surface of the yoke-side core member are formed integrally with the respective right and left leg portions of the first. divisional core. I-shaped leg-portion-side core members and spacers are attached in the cylindrical core mounting portion formed in each of the right and left leg portions. The surface of the yoke-side core member molded in the resin and the surface of the leg-portion-side core member are disposed so as to have a spacer therebetween. The two divisional cores are joined together by butting respective leg portions of the two divisional cores with each other to form an annular mold core, and a coil is wound around the mold core.

Abstract: A method is for making an electrical inductor. The method includes forming a first subunit having a sacrificial substrate, and an electrically conductive layer defining the electrical inductor and including a first metal on the sacrificial substrate. The method includes forming a second subunit having a dielectric layer and an electrically conductive layer thereon defining electrical inductor terminals and having the first metal, and coating a second metal onto the first metal of one of the first and second subunits. The method includes aligning the first and second subunits together, heating and pressing the aligned first and second subunits to form an intermetallic compound of the first and second metals bonding adjacent metal portions together, and removing the sacrificial substrate.

Abstract: An electromechanical transducer 180, motor structure 200 and voice coil winding support structure or bobbin 210 are configured to protect and transport heat away from a voice coil 220 which is would solely within the interior of bobbin 210 and configured for reciprocating movement in close proximity to an extended cooling pole piece 204. A compact, economical and efficient adaptation of a pancake style motor includes generous volume for a powerful magnet 208, while providing an extended, linear range of excursion and continuous cooling for the generously overhung voice coil 220.

Abstract: A winding assembly includes: slot-housed portions housed inside each of the slots of the stator core so as to form pairs that line up in an inner layer and an outer layer relative to a slot depth direction; first return portions at a first axial end of the stator core that link end portions of the slot-housed portions housed in the inner layer inside each of the slots and end portions of the slot-housed portions housed in the outer layer inside the slots that are (N?M) slots away; and second return portions at a second axial end of the stator core that link end portions of the slot-housed portions housed in the outer layer inside each of the slots and end portions of the slot-housed portions housed in the inner layer inside the slots that are (N+M) slots away.

Abstract: The invention relates to a transformer construction comprising a plurality of transformer cores configured to share magnetic flux paths and, as a result, at least one of the cores comprises a post and an associated sidewall having an effective cross-sectional area which is less than that of the post. Such a construction may be employed in a power conditioning unit, for example, for a photovoltaic module, which is configured to operate the cores out of phase from each other. Also described is a transformer winding comprising a longitudinal spine having a first turn emanating from a first portion of the spine in a first transverse direction and a second turn emanating from a second portion of the spine in a second transverse direction, wherein the second transverse direction is opposite to the first transverse direction.

Abstract: In a three phase transformer core, amorphous metal strips are wound into rings that are combined into frames and assembled to define cores with leg cross sections that have more than 4 sides to facilitate winding transformer windings onto the legs using winding tubes. The amorphous metal layers are secured relative to one another and the core made more rigid using resin, silicon steel layers included in the amorphous metal core, or by using strapping or tying devices.

Abstract: In a solenoid magnet assembly, and a method for manufacture thereof, the magnet assembly includes a number of concentrically aligned coils, each including a winding impregnated with a resin. Each coil is mechanically restrained so as to hold the coils in fixed relative positions relative to each other when forming the magnet assembly. The mechanical restraint can be formed by annular support sections bonded to the respective coils, lugs bonded to the respective coils, or by lugs that are at least partially embedded in a crust formed on a radially outer surface of the respective windings.

Abstract: An assembly includes a cylindrical magnet assembly, which includes comprises at least one coil mounted on a former. The assembly also includes a bore tube with a number of radially-directed retaining protrusions formed in a material of the bore tube, each of the number of radially-directed retaining protrusions configured to bear against a periphery of a corresponding cavity in the former.

Abstract: A method for manufacture of a conductor assembly. The assembly is of the type which, when conducting current, generates a magnetic field or in which, in the presence of a changing magnetic field, a voltage is induced. In an example embodiment one or more first coil rows are formed. The assembly has multiple coil rows about an axis with outer coil rows formed about inner coil rows. A determination is made of deviations from specifications associated with the formed one or more first coil rows. One or more deviations correspond to a magnitude of a multipole field component which departs from a field specification. Based on the deviations, one or more wiring patterns are generated for one or more second coil rows to be formed about the one or more first coil rows. The one or more second coil rows are formed in the assembly.

Abstract: A method for manufacture of a conductor assembly. The assembly is of the type which, when conducting current, generates a magnetic field or in which, in the presence of a changing magnetic field, a voltage is induced. In an example embodiment one or more first coil rows are formed. The assembly has multiple coil rows about an axis with outer coil rows formed about inner coil rows. A determination is made of deviations from specifications associated with the formed one or more first coil rows. One or more deviations correspond to a magnitude of a multipole field component which departs from a field specification. Based on the deviations, one or more wiring patterns are generated for one or more second coil rows to be formed about the one or more first coil rows. The one or more second coil rows are formed in the assembly. The magnitude of each multipole field component that departs from the field specification is offset.

Abstract: Integrated high frequency balanced-to-unbalanced transformers and inductors suitable for operation in high frequencies, such as radio frequencies. Embodiments disclosed give consideration to issues related to the layout of the top and bottom inductors for the minimization of capacitive effects between layers and methods of manufacturing thereof. The manufacturing process comprises forming of a first winding in a first metal layer; forming an insulating layer over at least the first metal layer; forming of a second winding in a second metal layer such that the second winding path has both a vertical and a horizontal displacement to the first conductive path, preferably with an overlap that is less than a full overlap; and forming shunts to ensure continuity of each of the first and second windings.

Abstract: An electronic component has a drum-shaped core member constituted by an assembly of soft magnetic alloy grains containing iron (Fe), silicate (Si) and chromium (Cr), a coil conductive wire wound around the core member, a pair of terminal electrodes connected to ends of the coil conductive wire, and an outer sheath resin part covering the wound coil conductive wire and constituted by a magnetic powder-containing resin; wherein there is an area where only the resin material in the magnetic powder-containing resin is permeated from the surface of the core member to a specified depth.

Abstract: An ultra-wideband assembly is provided. The assembly includes a non-conductive tapered core having an outer surface, a proximate end and a distal end being larger than proximate end. The assembly includes a conductive wire having a proximate end and a distal end and being wound about at least a portion of the non-conductive tapered core. The proximate end of the conductive wire extends away from the proximate end of the tapered core and is being conductively coupled to a micro-strip line of a circuit board. The distal end of the conductive wire extends away from the distal end of the tapered tapered core. The conductive wire contacts at least a portion of the outer surface of the non-conductive tapered core. The assembly includes a supporting bracket coupled to the non-conductive tapered core. The supporting bracket is configured to dispose the non-conductive tapered core at a predetermined angle to the circuit board.

Abstract: Disclosed herein are embodiments of devices for measuring electrical current and related systems and methods for forming and using such devices. According to certain embodiments, devices according to the present disclosure may comprise Rogowski coils. Also disclosed are systems and methods for forming a current measuring device using a bobbin that may allow for the use of a continuous length of wire for all windings associated with the current measuring device. Automated manufacturing techniques may be utilized to facilitate the manufacture of devices for measuring electrical current and/or may reduce the cost of such devices. Various embodiments disclosed herein include the use of a bobbin that may be selectively configured between a linear configuration and a closed configuration. One or more current sensors disclosed herein may be utilized in connection with a motor management relay or other type of intelligent electronic device.

Abstract: An electrical apparatus includes a magnetic core, and a bobbin extending about and partially covering the magnetic core. The bobbin is formed from a thermally conductive material. An electrical conductor forms a winding that wraps about the bobbin.

Abstract: A method for manufacturing a local coil for a magnetic resonance tomography device includes manufacturing the local coil with a flat cross-section. The method also includes deforming the local coil from the flat cross-section into a curved cross-section.

Abstract: An implantable medical lead (1) comprises multiple electrodes (22, 24, 26, 28) arranged at a distal end (2), multiple electrode terminals (32, 34, 36, 38) at a proximal end (3) and a lead body (4) with an insulating tubing (40). A conductor coil (10) comprises a coiled tubular insulator (19) having multiple separate lumens (12, 14, 16, 18). Each lumen (12, 14, 16, 18) houses a respective conductor (11, 13, 15, 7), which is movable in the lumen (12, 14, 16, 18) relative the coiled tubular insulator (19). The conductor coil (10) is arranged in a bore (42) of the insulating tubing (40) and each conductor (11, 13, 15, 7) is electrically connected to one of the electrodes (22, 24, 26, 28) and one of the electrode terminals (32, 34, 36, 38).

Abstract: A method of reducing defect heights of iron mound defects on a mill glass coated electrical steel, comprises contacting at least a portion of a surface of a mill glass coated electrical steel with an acidic solution for a contacting time sufficient to reduce an average height of iron defects on the surface to a an average height in a range of 0 percent to 150 percent of the thickness of the mill glass coating, without effectively removing the mill glass coating. After contacting, the acid contacted mill glass coated electrical steel is rinsed with water and dried.

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

Abstract: A magnet assembly has a number of axially-aligned coils, the radial mid-point of each coil being axially-aligned with a portion of a radial extent of an adjacent coil in the assembly. Compression blocks are provided between adjacent coils at circumferential intervals, to retain the coils in fixed relative positions.

Abstract: A method of joining the ends of wire windings for a motor stator or the like includes preparing a surface at each end (e.g., by removing any enamel coating), deforming the surfaces to produce knurls, striations, and the like, and then ultrasonically bonding the two surfaces to produce the bond between windings, thereby providing a joint with improved strength.

Abstract: A device for controlling an electric field at a high voltage component including a resistive layer for field control, an insulating layer arranged on the resistive layer and a semi-conducting or conducting layer arranged on the insulating layer. The three layers meet at a triple point where the insulating layer ends. An interface between the resistive layer and the insulating layer makes in the triple point an angle to the semi-conducting or conducting layer of 60°-120°.

Abstract: The present invention discloses a coil part including: a first coil body including a first magnetic substrate, a first coil pattern provided on the first magnetic substrate, and a first insulating layer covering the first coil pattern; a second coil body including a second magnetic substrate corresponding to the first magnetic substrate, a second coil pattern provided on the second magnetic substrate to correspond to the first coil pattern, and a second insulating layer covering the second coil pattern; and a ferrite composite interposed between the first insulating layer and the second insulating layer to couple the first coil body and the second coil body and having a spacer ball inside. According to the present invention, it is possible to prevent process defects generated during a manufacturing process of an existing coil part using a ferrite substrate, improve process efficiency and productivity, and reduce manufacturing costs.

Abstract: Systems and methods for an electric choke are provided. The choke may be provided as part of a power transmission arrangement that includes a cable for electrically coupling a power source and a powered device having a ground node and a wire separate from the cable providing a path for a common-mode current through the ground node. The power transmission arrangement also includes an unbalanced choke coupled between the power source and the powered device, wherein a number of turns of the cable in the choke is different than a number of turns of the wire in the choke.

Abstract: A magnetizing coil unit and a method of making a magnetizing coil unit is provided. The coil includes a solenoid coil having a coiled copper sheet in which the width of the copper sheet is equal to the height of the solenoid coil. A magnetizing assembly includes a plurality of magnetizing coil units.

Abstract: An integrated 3-dimensional inductor device is provided. The inductor device includes a substrate having an electrical trace and a 3-dimensional inductor attached to the substrate. The inductor includes a magnetic core and a coil whose windings are formed from the electrical traces of the substrate and conductive material in the interconnect vias.

Abstract: Generally, methods and processes for assembling magnetic components are presented herein. More specifically, conductors are wound around a substantially hollow bobbin. Portions of the conductors may be temporarily positioned outside the bobbin through slots in the flanges of the bobbin during the assembly process. Insulating layers may be wrapped around the conductors. The center legs of a pair of magnetic core halves may be inserted into the bobbin. The base of the magnetic core halves may have a passage to allow a conductor to pass therethrough at a height less than the height of the base.

Abstract: A method of making a planar coil is disclosed in the present invention. First, a substrate having a trench is provided. Then, a barrier and a seed layer are formed on the substrate in sequence. An isolative layer is used for guiding a conductive material to flow into a lower portion of the trench such that accumulation of the conductive material at opening of the trench is prevented before the lower portion of the trench is completely filled up, thereby avoiding gap formation in the trench.

Abstract: Stator winding (10) for an electric machine, in particular for a generator of a motor vehicle, the stator winding (10) being embodied as an ordered stator winding (10), and the stator winding (10) being embodied in at least two axially spaced-apart levels (22, 24) in a winding head (13). The invention also relates to an electric machine and a method for manufacturing a stator winding (10) of an electric machine.

Abstract: A wire assembly includes a plurality of strength members, a first coating layer disposed on the strength members, and a conductive element helically wound about the first coating layer. The conductive element has a length associated with a predetermined resistance. A second coating layer is disposed on the conductive element, an the second coating layer is applied to the conductive element and the first coating layer via pressure extrusion to eliminate air gaps between at least a portion of the first coating layer and the second coating layer. A method of forming the wire assembly includes coating the strength members with the first coating layer, helically winding the conductive element about the first coating layer, and applying the second coating layer to the conductive element and the first coating layer via pressure extrusion to eliminate air gaps between at least a portion of the first and second coating layers.

Abstract: A method provides a portion of a transformer by forming a core by providing transformer core material, cutting individual laminations and bending them into generally C-shaped members, stacking some members to define a first core portion having a main leg and two opposing end legs, stacking other members to define a second core portion having a main leg and two opposing end legs, arranging the main legs in a back-to-back manner to define the core having a core leg defined by the two main legs, and opposing core yokes, defined by the end legs. Conductive material is wound directly around the core leg to form a primary winding and secondary winding in any order of arrangement, thus providing a first transformer portion. The transformer portion may be part of a single transformer or, when second and third transformer portions are provided, as part of a three-phase transformer.

Abstract: A method of manufacturing a coil device includes inserting planar insulating sheets into a single conductor formed in a solenoidal coil shape from a direction intersecting with a winding axis direction.

Abstract: An inductive component includes: a ferromagnetic core; a coil made of aluminum and having a winding portion wound around the ferromagnetic core for a predetermined number of turns, and two extending portions extending respectively from two ends of the winding portion; and two terminals made of copper. Each terminal wraps around a respective one of the extending portions.

Abstract: A coil and electric shielding arrangement for a dry-type transformer includes an electric shielding device arranged at a distance from a winding, at an axial end of the winding perpendicular to a longitudinal axis of the transformer, and parallel to a top surface of a coil that is wound around the axis such that the electric shielding device covers a cross-sectional area of the winding perpendicular to the longitudinal axis. An insulation material attached to the winding and to the electric shielding device establishes a first distance between the winding and the electric shielding device along the longitudinal axis such that the winding is shielded against another electric field. The winding and the electric shielding device are casted in a block which insulates the electric shielding device from the electric field of the winding by establishing a second distance between the winding and the electric shielding device.

Abstract: A method for winding a coil on an object, wherein the coil includes a plurality of first coils and a plurality of second coils, may have winding the first coils on an exterior circumferences of the second coils, wherein an outer circumferences of the respective second coil is enclosed and in contact with outer circumference of at least three first coils, and wherein cross-sectional area of the second coil is smaller than that of the first coil, and wherein the outer circumference of the at least three first coils are in contact each other.

Abstract: There is provided a system for readily and efficiently fabricating a wound coil composed of a bobbinless coil. The system includes a coil winding device having an upper jig to which an upper plate is attached and a lower jig to which a lower plate is attached which are provided so as to be relatively displaceable and a tension device for applying predetermined tension to a wire rod fed from a wire rod supplying source. The coil winding device is provided with a claw section having first through third split claws that function as a winding section around which the wire rod is wound between the upper and lower plates and that slide in a radial direction when the upper jig is assembled coaxially with the lower jig.

Abstract: A stator coil producing method and a stator coil production machine. The stator coil is used in an electric rotating machine. The stator coil production machine includes a rotary retainer which retains and moves shaping press pairs along a looped path to press or shape portions of a conductor wire into in-slot portions to be disposed in slots of a stator core and coil-end portions which extend outside the slots. The method comprises a coil-end portion shaping step of bringing press members of each of the shaping press pairs close to each other in sequence to shape the coil-end portions and an in-slot portion shaping step of advancing the shaping press pairs on the looped path in contact with the cam mechanism and also moving selected ones of the shaping press pairs in sequence in a direction perpendicular to the path to shape the in-slot portions.

Abstract: A manufacturing method of a coil component comprises the steps of: providing a first permeance element; sticking a strip-like element to a first area of a first surface of the first permeance element; providing a second permeance element; disposing a winding structure between the first permeance element and the second permeance element, or around at least one of the first permeance element and the second permeance element; and connecting the first permeance element and the second permeance element by a connecting material stuck to a second area, which is without the strip-like element, of the first surface.

Abstract: An ignition coil assembly and a method of assembling the ignition coil assembly including a first spool, a first coil, and a second spool. The first coil is wound around a first spool outer surface. The first spool and the first coil are disposed within a cavity of the second spool and an electrically insulating material injected into an annular space defined between a first coil outer surface and a second spool inner surface. The first spool is configured to allow a decrease of a circumference of the first spool when the first coil is wound around an outer surface of the first spool. Decreasing the circumference of the first spool increases the annular space sufficient to inject the electrically insulating material into the annular space without creating substantial voids in the electrically insulating material.

Abstract: A manufacturing method of a coil component comprises a forming step to form a first coil and a second coil connecting to each other, wherein the first coil is disposed at the inside of the second coil; a disposing step to dispose a part of a tail segment of the first coil on a last-loop segment of the second coil along a contour of the last-loop segment of the second coil; and a covering step to cover the first coil and the second coil.