Abstract: A tape wound inductor core device, inductors including same and methods of manufacture. Tape wound material may be cut and/or shaped into “pucks” that have an exterior surface made up of or defined substantially by the edge surfaces of the layers of the constituent conductive material, with all or most of the broad surfaces disposed inwardly, thereby reducing eddy currents and associated losses. Various puck configurations, inductor arrangements and fabrication techniques are disclosed.

Abstract: In accordance with an embodiment of the application a method of forming an integrated magnetic device is described. A prepreg or core is mounted on a carrier. A winding layer is plated and patterned on the prepreg or core. Vias are plated. The silicon is placed on a die attach pad, ensuring sufficient clearance of die to vias and d/a char. The assembly is laminated and grinded to expose the vias. A 2nd layer of vias is provided by sputtering or plating followed by laminating assembly; and grinding assembly to expose vias. The windings are plated and patterned. A solder mask (SMSK) is applied and assembly finished.

Abstract: A high voltage transformer arrangement for supplying power to a high voltage tank assembly is disclosed. The high voltage transformer arrangement includes a first core arranged in the high voltage tank assembly and a secondary winding configured on the first core, a second core positioned outside of the high voltage tank assembly and at a predefined distance from the first core, and a primary winding configured on the second core. The second core and the primary winding transfers current received from an external power source to the first core and secondary winding for supplying power to the high voltage tank assembly.

Abstract: A wireless charging coil is provided herein. The wireless charging coil comprising a first stamped coil having a first spiral trace, the first spiral trace defining a first space between windings, and a second stamped coil having a second spiral trace, the second spiral trace defining a second space between windings, wherein the first stamped coil and second stamped coil are planar to and interconnected with one another, such that the first stamped coil is positioned within the second space of the second stamped coil, and the second stamped coil is positioned within the first space of the first stamped coil.

Abstract: A conductor assembly and method for constructing an assembly of the type which, when conducting current, generates a magnetic field or which, in the presence of a changing magnetic field, induces a voltage. In one embodiment the method provides a first insulative layer tubular in shape and including a surface along which a conductor segment may be positioned. A channel formed in the surface of the insulative layer defines a first conductor path and includes a surface of first contour in cross section along a first plane transverse to the conductor path. A segment of conductor having a surface of second contour in cross section is positioned at least partly in the channel and extends along the conductor path. Along the first plane, contact between the conductor surface of second contour and the channel surface of first contour includes at least two separate regions of contact.

Abstract: A magnetic device is provided. The magnetic device includes a magnetic core and a conductive winding inductively coupled to the magnetic core. The conductive winding includes a first terminal segment, a second terminal segment, and an inductive segment electrically coupled in series therebetween. The first terminal segment includes a current sensing element.

Abstract: A low cost, high performance electronic device for use in electronic circuits and methods. In one exemplary embodiment, the device includes an interleaved flat coil and coil winding arrangement that ensures low leakage inductance while using a combination of flat coil windings and self-bonded Litz coil windings. The flat coil windings further include features that are configured to mate with the header assembly terminal pins which substantially simplify the manufacturing process. Methods for using and manufacturing the aforementioned inductive devices are also disclosed.

Abstract: An apparatus including a first layer having a first coil; a second layer having a second coil, where the first and second coils are stacked relative to each other and configured to be located at an aperture of a housing member including electrically conductive material; and a third layer located under the second layer. The third layer includes a ferrite member located under the second coil such that the second coil is between the first coil and the ferrite member. The first coil or the second coil has a substantially “8” shape.

Abstract: Coil assembly (1) comprising a planar coil (2) comprising a plurality of turns (15) arranged in a trench (10) in a first magnetic core plate (3) and a second magnetic core plate (8), where the first magnetic core plate (3) and second magnetic core plate (8) are in direct contact with each other or separated by an electrically insulating insulator layer (5) with a thickness (t) equal to or less than 50 ?m and least one tap (6) extends from the coil (2) in a respective via hole (11) through the first magnetic core plate (3) to a respective contact pad (7), wherein the coil (2) and the tap (6) are integrally formed.

Abstract: A cylindrical magnet assembly has at least one coil mounted on a former, assembled to a bore tube by a number of inserts within holes formed in a material of the former. Each insert can bear on a dished radially outer extremity of a radially-outwardly directed protrusion or each insert can bear on a radially outer concave surface of a radially-inwardly directed protrusion.

Abstract: Methods for the manufacture of an electromagnetic coil assembly are provided. In one embodiment, the method includes joining a first end portion of a braided lead wire to a coiled magnet wire. A dielectric-containing material is applied in a wet-state over the coiled magnet wire and over the first end portion of the braided lead wire. The dielectric-containing material is cured to produce an electrically-insulative body in which the coiled magnet wire and the first end portion of the braided lead wire are at least partially embedded. Prior to application of the dielectric-containing material, the braided lead wire is at least partially impregnated with a masking material deterring wicking of the dielectric-containing material into an intermediate portion of the braided lead wire. In certain cases, the masking material may be removed from the braided lead wire after curing, and the electrically-insulative body may be sealed within a canister.

Abstract: A magnetometer is described, having a substrate and a magnetic core, the substrate having an excitation coil for generating a magnetic flux in the magnetic core; and the excitation coil having a coil cross section, which is aligned generally perpendicular to a main plane of extension of the substrate. The magnetic core is situated outside the coil cross section.

Abstract: A device may include a multiple inductive coils arranged concentrically for operating according multiple modes of wireless power transfer. The device may include multiple layers of magnetic shields to protect device components from the effects of the magnetic field used for power transfer. Construction and material of multiple layers of shields may be based on addressing individually the different parameters of the multiple modes of operation and based on the combined effect of the layers in each mode of operation. In some examples, the device may include first and second ferrite shields each having different magnetic properties.

Abstract: An armature assembly apparatus for assembling an armature of an electrical machine is provided. The armature assembly apparatus has an armature holding apparatus to hold a partially assembled armature such that a rotation axis of the armature is horizontal. The armature assembly apparatus has a rotating device for rotating the partially assembled armature about a rotation axis. The armature assembly apparatus also has a ring segment conveyance for conveying an armature ring segment to a mounting position relative to a free ring segment portion of the partially assembled armature.

Abstract: A method of fabricating an electric machine stator includes inserting one or more electrical coils into a form and partially curing the one or more electrical coils. The method also includes populating the electric machine stator with the one or more electrical coils and curing the electric machine stator with one or more electrical coils.

Abstract: An electromagnetic component includes a coil portion with a multi-layer stack structure, a molded body encapsulating the coil portion, and two electrodes respectively coupled to two terminals of the coil portion. The coil portion is fabricated using plating, laminating and/or pressing manufacturing techniques.

Abstract: An inductive device may include a pair of half-shell magnetically-conductive housings joined together and defining an enclosed cavity between them. The inductive device may also include primary and secondary windings provided spatially within the cavity providing magnetic coupling between them. The windings may be electrically insulated from each other and terminals of the primary and secondary windings may traverse to an exterior of the inductive device.

Abstract: A nickel strip is made from a starting material of solid cathode sheets having a minimum nickel content of 99.94% by weight and a maximum trace element content, in ppm by weight, of <35 carbon, <5 sulphur, <14 manganese, <11 magnesium, <11 aluminum, <25 titanium, and <15 silicon. The sheets are hot-rolled individually in a single layer/ply. The sheets are then joined to form the strip.

Abstract: A method of producing a transformer module by placing at least one transformer which includes a core, a primary winding, and a secondary winding at a bottom surface of a case at which a plurality of external terminals are provided. The method comprising placing two support columns on the bottom surface, placing the bottom surfaces of cores near the lead-out points of the leads of the windings at the two sides of the cores on core support parts of the two support columns to support them, stringing leads at the two sides of the cores to the external terminals and electrically joining them, removing the two support columns so that the bottom surfaces of the cores are placed on the bottom surface of the case, then fastening the cores to the bottom surface of the case to produce a transformer module where the leads from the cores are given excess length.

Abstract: A magnetic device includes an electrically insulating body and a conductor coil. The insulating body defines an internal cavity for a magnetic device core and a coolant channel routed about the internal cavity. The conductor coil extends through the insulating body and winds about the internal cavity. The electrically insulating body electrically insulates the internal cavity and coolant channel from the conductor coil.

Abstract: A transformer apparatus includes: a case with a component mounting surface; an external-terminal provided on a wall adjacent to the component mounting surface of the case; a transformer provided on the component mounting surface and including a magnetic core and a winding; and a support provided in a position between the external-terminal and the core on the component mounting surface, and including a first-slit in a top surface of the support, the first-slit holding a first-conductor of the winding drawn from the core and a second-conductor drawn from the external-terminal, wherein the first-conductor is held at one end of the first-slit by a conductive member, the second-conductor is held at the other end of the first-slit by the conductive member, the first-conductor and the second-conductor are electrically connected through the conductive member, and the first-conductor and the second-conductor have surplus lengths.

Abstract: A method of manufacturing an inductor includes a lamination step, a division step, a firing step, and a plating step. In the lamination step, a laminate including an insulator, a coil body, and external electrodes is formed. That is, in the lamination step, insulating layers having wide filling conductors, insulating layers having narrow filling conductors, and conductor patterns having external electrode patterns are laminated. As a result, the conductor patterns form the coil body, and the wide filling conductors, the narrow filling conductors, and the external electrode patterns form the external electrodes. The narrow filling conductors have a width that is less than the widths of the wide filling conductors and the external electrode patterns, and recesses and projections are provided in the external electrodes.

Abstract: A method to form a choke is disclosed, wherein the method comprises: encapsulating a hollow coil by a molding body; forming a first core, wherein the first core comprises a pillar; and disposing at least one first portion of the pillar inside the encapsulated hollow coil. The method avoids the overflow or vertical flow issue during a molding process for encapsulating a coil that has been wound on a core already.

Abstract: A method for preparing a field coil winding assembly including cleaning a plurality of copper coils followed by developing, after the cleaning, a copper oxide layer on each of the copper coils by oxidizing each of the copper coils in a solution. After the developing, each of the copper coils is rinsed followed by drying. After the drying, a turn insulation system is applied to each of the copper coils. The turn insulation system includes a turn insulation and an adhesive. The turn insulation includes at least one of a glass fiber re-enforced polyamideimide, a glass fiber re-enforced polyester, or a glass fiber re-enforced high temperature novolac epoxy. After the applying, each of the copper coils with the turn insulation system is cured. The plurality of copper coils with the turn insulation system are stacked in each of a plurality of rotor slots in a rotor.

Abstract: A coil component has a wound coil, a coil magnetic body, and an exterior body. The coil magnetic body has a magnetic core inside winding of the wound coil. The exterior body covers a surface of the coil magnetic body. This coil component has a mount surface, and a thermal conductivity in a direction parallel to a surface of the exterior body is greater than a thermal conductivity in a direction perpendicular to the surface of the exterior body.

Abstract: Several embodiments of a circuit device using principles of planar Litz wire construction are disclosed using flexible printed circuit boards on which a given set of conductors is located on one surface only. The FPCBs are folded at strategic locations to effectively cause conductors in adjacent parallel planes to effectively cross one another to realize the advantages of braided Litz wire conductors, but without the use of vias or circuit interconnections between opposite sides of any given FPCB or between different sections of a continuous FPCB wherein each section defines its own coil or coil set.

Abstract: Provided are an opposed iron core transmitting rotation motion, a manufacturing method thereof, and an electromagnetic fan clutch formed by the opposed iron core. The opposed iron core includes iron core grooves (12; 13) axially arranged in a back-to-back manner on an electromagnetic iron core body (11). The manufacturing method of the opposed iron core includes: directly drawing the iron core body (11) to form the iron core grooves arranged in the back-to-back manner, or directly spinning the iron core body (11) to form the iron core grooves arranged in the back-to-back manner. The electromagnetic fan clutch formed by the opposed iron core has a first actuation gap (841) and a second actuation gap (842) respectively on two sides of the electromagnetic iron core body (11) of an opposed iron core apparatus.

Abstract: A magnetic core is provided. The magnetic core includes a magnetic base and a magnetic plate. The magnetic base includes a first U-core, a second U-core, and a spacing member. The first U-core has a relatively high magnetic permeability, and includes a first surface having a first winding channel defined therein. The second U-core has a relatively high magnetic permeability, and includes a second surface having a second winding channel defined therein. The first and second surfaces are substantially coplanar with one another. The spacing member is connected to the first and second U-cores such that a gap having a relatively low magnetic permeability is formed between the first and second U-cores. The magnetic plate is coupled to the magnetic base such that the magnetic plate substantially covers the first and second surfaces.

Abstract: A method of producing a stator winding for a stator of an electrical machine includes positioning a phase winding segment of the stator winding in a same plane in a serpentine manner in a first direction (X) and in a shape of a wave in a second direction (Y) transverse to the first direction. The method includes bending regions (A, B, C) of the phase winding segment toward one another along a folding line to form a lap winding including positioning regions (C) parallel to each other connected by regions (B) where the regions (B) cross the at least one folding line (108). The phase winding is formed with a continuous wire.

Abstract: A distribution transformer having a slot-and-tab core frame assembly. The core frame (17) encloses a transformer core (11) having at least one phase and provides compression on the core yokes and end members of the transformer to bind the assembly together. First and second clamps (10, 24) of the core frame contain receiving slots (34) for the tabbed (18, 28), longitudinal side supports (20), creating an interlock when connected. For larger transformers, the tabbed side supports may be alternatively comprised of a subassembly of end plates, cams, and tabbed locking plates, encompassing a sturdy locking mechanism.

Abstract: A transformer core manufacturing apparatus for manufacturing an annular transformer core having thin plates formed of magnetic materials laminated includes an uncoiler unit which allows a plurality of uncoilers each having a thin plate magnetic material coiled hoop-like to uncoil the magnetic material, a carrier unit for guiding a plurality of the magnetic materials uncoiled from the plurality of the uncoilers as a single group of magnetic body, a first alignment unit for aligning the carried group of the single magnetic body in a width direction, a cut-off unit for cutting the magnetic body aligned by the first alignment unit in a predetermined dimension, a laminating unit for laminating a plurality of the groups of the magnetic body cut by the cut-off unit, a second alignment unit for aligning the magnetic body laminated on the laminating unit, and a control unit for controlling operations of the above cited units.

Abstract: A polarized relay comprising an electromagnet, a two-pole or three-pole permanent magnet, an armature, and switches, which are mounted in and on a shelf-like support component. The support component accommodates magnetic flux pieces and the permanent magnet in an upper cavity, and the permanent magnet is magnetized while the electromagnet is still outside the support component. Subsequently, the electromagnet is inserted into lower cavity of the support component and the rest of the components of the relay are mounted.

Abstract: A method for making a magnetic assembly comprises the following steps: twisting a first to eighth magnetic wires to form a bundle of wires having a first end and an opposite second end; providing a magnetic core; winding the bundle of magnetic wires around the magnetic core; sorting the first end and the second end of the bundle of wires to form individual first ends and individual second ends of the first to eighth wires; picking out the second ends of the first wire and the second wire, and the first ends of the third wire and the fourth wire to form a centre tap of a primary coil of a transformer; and picking out the second ends of the fifth wire and the sixth wire, and the first ends of the seventh wire and the eighth wire to form a centre tap of a secondary coil of the transformer.

Abstract: A method for making a shielded inductor by: winding a metal wire material into a conducting coil and bending two distal ends of the metal wire material into a respective end piece, bonding a magnetic core to the center of the conductive coil, making a metal sheet member into a metal bracket having a frame body, solder points and connection strips, installing the conductive coil in the metal bracket and electrically soldering the end pieces of the conductive coils to respective soldering points at the metal bracket, mixing a magnetic material with a plastic material and processing the mixture into plastic grains, injection-molding the plastic grains onto the conductive coil to form an inductor body, and separating the respective connection strips with the inductor body from the metal bracket and bending the separated connection strips onto the bottom wall of the inductor body.

Abstract: A method of manufacturing a solenoidal magnet structure, comprising the steps of providing a collapsible mold in which to wind coils; winding wire into defined positions (88) in the mold to form coils (34); placing a preformed tubular mechanical support structure (102, 120) over the coils (34) so wound; impregnating the coils and bonding them to the mechanical support structure by applying a thermosetting resin and allowing the thermosetting resin to harden; and collapsing the mold and removing the resultant solenoidal magnet structure comprising the resin impregnated coils and the mechanical support structure from the mold as a single solid piece.

Abstract: The present invention relates to a coil type unit for wireless power transmission, a wireless power transmission device, an electronic device, and a manufacturing method of a coil type unit for wireless power transmission. A coil type unit for wireless power transmission according to the present invention includes a coil pattern in the form of a wiring pattern; a magnetic portion having the coil pattern attached to one surface thereof; and an adhesive portion interposed between the magnetic portion and the coil pattern to bond the magnetic portion and the coil pattern, wherein the magnetic portion is formed by laminating one or more conductive sheets with one or more magnetic sheets and integrally firing the laminated sheets, and the magnetic portion has conductive holes in the position, where both ends of the coil pattern are disposed, to electrically connect the both ends of the coil pattern and the conductive sheet.

Abstract: Toroidal transformers are currently used only in low-voltage applications. There is no published experience for toroidal transformer design at distribution-level voltages. Toroidal transformers are provided with electrostatic shielding to make possible high voltage applications and withstand the impulse test.

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: Provided are a reactor which can perform step-up/step-down operations and soft switching with a small size and a smaller leakage inductance, and a method of adjusting a leakage inductance of the reactor. A reactor 1A includes a magnetic core 10A having a pair of inner core portions and forming a closed magnetic path, a main coil 11A having main coil elements 11a and 11b, and a sub-coil 12A having sub-coil elements 12a and 12b. The coil elements 11a and 12a are concentrically layered over one of the inner coil portions, and the coil elements 11b and 12b are concentrically layered over the other inner coil portion. One end portion of a wire 11w of the main coil 11A and one end portion of a wire 12w of the sub-coil 12A are joined to each other. A spacing between adjacent turns constituting the sub-coil element 12a (12b) is wider than that between adjacent turns constituting the main coil element 11a (11b). Thus, the reactor 1A has a smaller leakage inductance.

Abstract: A microtechnical component for a magnetic sensor device or a magnetic actuator includes: a magnetic core oriented along an axis; a first drive coil having windings arranged in a first direction of rotation about the magnetic core; a contact, via which a first current flow is created in a first current direction through the first drive coil; and a second drive coil having windings arranged in a second direction of rotation about the magnetic core, the first and second directions of rotation differing from one another. Simultaneously with the first current flow, a second current flow is created via the contact in a second current direction opposite the first current direction through the second drive coil.

Abstract: A low profile surface mount electromagnetic component such as a power inductor includes first and second core pieces arranged side by side and having longitudinal side walls facing one another. A preformed coil winding includes vertical legs that are received in vertical slots of the facing longitudinal sidewalls of the component. Inset depressed sections are provided in the top surfaces of the first and second magnetic core pieces and receive a main winding section of the coil winding. Surface mount terminal tabs extend on the bottom surfaces of both the first and second magnetic core pieces.

Abstract: Method for producing a distributed lap winding for polyphase systems, in particular for alternators, wherein, in a first step, a chain of laps is formed with a linking direction, characterized in that, in a further step, at least one lap is rotated with its lap sides at right angles to the linking direction such that at least one lap side of one lap is arranged alongside at least one lap side of another lap such that the at least one lap side of one lap and the at least one lap side of another lap are arranged at a position which corresponds to a slot position.

Abstract: A tank for a transformer includes a left side wall, a right side wall opposing the left side wall, a front wall, a rear wall opposing the front wall, and a trapezoidal-shaped base. Each of the left side wall, the right side wall, the front wall and the rear wall extends from the base so as to define a trapezoidal-shaped tank having an open end in communication with an interior space. The right and left side walls, and the rear wall are constructed and arranged so that the open end slants downwardly from front to back of the tank. A cover is adhered to the tank to cover the open end. The tank is constructed and arranged to house transformer components in the interior space.

Abstract: A method for manufacturing a low profile, magnetic component. The method includes stacking a the plurality of substantially planar and flexible magnetic powder sheets, locating a preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack, and pressure laminating the flexible magnetic powder sheets around the preformed multiple turn conductive winding to define a magnetic core containing the winding.

Abstract: An improved choke assembly for a power electronics device is provided. More specifically, a choke assembly with improved protection from environmental conditions such as dirt and water is provided. An improved choke assembly may include an insulative housing for an inductor coil that seals the inductor coil from the environment.

Abstract: A method for manufacturing an electromagnetic relay includes: forming an iron core that has an end face and a groove which goes across the end face; fitting a shading coil that is fitted in the groove; and fixing the shading coil to the iron core by applying caulking processing to a plurality of areas in the end face which sandwich the groove.

Abstract: A structure is disclosed, comprising: a first magnetic core portion comprising: a first plurality of leg posts that are to be surrounded by a first set of windings; and a first plurality of center portions that are not to be surrounded by windings; and a second magnetic core portion comprising: a second plurality of leg posts that are to be surrounded by a second set of windings; and a second plurality of center portions that are not to be surrounded by the second set of windings, wherein the first set of center portions and the second set of center portions are configured to provide a plurality of physically separate magnetic flux paths.

Abstract: The present invention relates to an injector for use in gas phase analytical systems and methods comprising a metal housing, provided with a carrier gas inlet, a split outlet, a column outlet of the injector, a sample inlet, a liner, and a heater device comprising at least one coil for radio frequency inductive heating the housing with a predetermined temperature program and for providing a predetermined spatial temperature profile in the injector. The injector according to the invention allows performing gas phase analyses, especially GC analyses with reduced discrimination. Advantages of heating with a heater device comprising a coil for inductive heating include a homogeneous heating profile of the housing including parts connected thereto, with heating rates that can be varied widely. A further advantage is that the injector can be operated as a conventional S/SL injector at a predetermined temperature, or as PTV injector or thermal desorption injector with certain predetermined temperature programs.

Abstract: A stator for an electric rotating machine includes a stator core which has a plurality of slots and a stator winding which is provided at the stator core. The stator winding has a plurality of conductor segments each of which includes an inner conducting body accommodated in the slot of the stator core and coil ends exposed from the slot, and weld portions which are connected with each other by welding the conductor segments at at least one of the coil ends. The weld portions are annularly disposed with an interval therebetween. The weld portions are coated with an insulating resin material. The resin material is formed of a plurality of layered insulating films.

Abstract: A coil strand is wound on an insulator to produce a divided core member, and then the divided core member is placed on a table. While the table rotates about its axis, ends of the coil strands are inserted into lead end holding grooves, which are defined in a surface of the insulator on an outer circumferential edge of a stator and which extend along a circumferential direction of the stator.