By Assembling Coil And Core Patents (Class 29/606)
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Patent number: 8056215Abstract: A first tool set holds a wire covered with an insulation film at a bending point of the wire to protrude the wire from the first tool set. A second tool set holds the protruded portion of the wire. The second tool set is rotated about the first tool set to bend the wire along a wall of the first tool set and to form a boundary corner in the wire at the same radius of curvature as the wall. The wire is released from the second tool set and is moved to place the first tool set at another bending point while protruding from the first tool set. The second tool set is placed at the protruded portion of the wire. When the wire is bent at a predetermined number of bending points and is rounded, a stator coil formed in a corrugated shape is manufactured.Type: GrantFiled: April 6, 2009Date of Patent: November 15, 2011Assignee: Denso CorporationInventors: Masahiro Takada, Kuniharu Teshima, Hideji Shimaoka, Toshiaki Oohara
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Patent number: 8058764Abstract: A winding former with a winding support between a first plate and a second plate for a saddle coil winding made up from a thin layer HTSC, which is destined for a cylindrical armature of an electrical machine, and which has two longitudinal legs parallel to the armature axis between two winding ends, wherein the winding support for each winding end has a bearing surface, which enables the thin layer HTSC to be wound to form a saddle coil without damaging the HTSC thin layer.Type: GrantFiled: August 22, 2008Date of Patent: November 15, 2011Assignee: Zenergy Power GmbHInventor: Jan Wiezoreck
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Publication number: 20110260825Abstract: Miniaturized magnetic components for electronic circuit board applications include enhanced magnetic composite sheets facilitating increased direct current capacity and higher inductance values. The components may be manufactured using relatively simple and straightforward lamination processes.Type: ApplicationFiled: April 23, 2010Publication date: October 27, 2011Inventors: Frank Anthony Doljack, Hundi Panduranga Kamath
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Publication number: 20110260823Abstract: A transmission line impedance transformer may include a printed circuit board (PCB) having a dielectric layer and an electrically conductive layer thereon defining a medial interconnection portion, and first and second lateral loop portions extending laterally outwardly from opposing first and second sides of the medial interconnection portion. The PCB also may have first ferrite body receiving openings therein adjacent the first lateral loop portion and second ferrite body receiving openings therein adjacent the second lateral loop portion. The transmission line impedance transformer may also include a first ferromagnetic body extending through the first ferrite body receiving openings to surround the first lateral loop portion, and a second ferromagnetic body extending through the second ferrite body receiving openings to surround the second lateral loop portion.Type: ApplicationFiled: April 27, 2010Publication date: October 27, 2011Applicant: Harris CorporationInventor: Andrew Mui
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Publication number: 20110258842Abstract: 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.Type: ApplicationFiled: July 1, 2011Publication date: October 27, 2011Applicant: Medtronic Navigation, Inc.Inventors: John H. Dukesherer, Bruce M. Burg, Bradley A. Jascob, Paul Kessman
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Publication number: 20110258843Abstract: 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.Type: ApplicationFiled: July 1, 2011Publication date: October 27, 2011Applicant: Medtronic Navigation, Inc.Inventors: John H. Dukesherer, Bruce M. Burg, Bradley A. Jascob, Paul Kessman
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Publication number: 20110260824Abstract: A transformer assembly. In some embodiments, the transformer assembly comprises a transformer, comprising a magnetic core; a primary winding wound around the magnetic core, wherein the primary winding comprises one or two turns of a first conductive material; and a secondary winding wound around the magnetic core, wherein the secondary winding comprises a plurality of turns of a second conductive material, and wherein a diameter of the magnetic core is sized such that the transformer achieves a first inductance with a core loss comparable to a winding loss.Type: ApplicationFiled: April 13, 2011Publication date: October 27, 2011Applicant: ENPHASE ENERGY, INC.Inventors: MARTIN FORNAGE, DONALD RICHARD ZIMMANCK
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Patent number: 8042260Abstract: The claimed invention pertains to methods of forming one or more inductors on a semiconductor substrate. In one embodiment, a method of forming an array of inductor core elements on a semiconductor substrate that includes integrated circuits is disclosed. A first set of spaced apart metallic core elements are formed over the substrate. Isolation sidewalls are then formed on side surfaces of the core elements. Afterward, a second set of metallic core elements are formed over the substrate. The first and second sets of core elements are substantially co-planar and interleaved such that only the isolation sidewalls separate adjacent core elements. Particular embodiments involve other processing operations, such as the selective electroplating of different types of metal to form core elements and/or the deposition and etching away of an isolation layer to form isolation sidewalls on the core elements.Type: GrantFiled: October 13, 2008Date of Patent: October 25, 2011Assignee: National Semiconductor CorporationInventors: Peter J. Hopper, Peter Johnson, Peter Smeys, Andrei Papou
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Patent number: 8028396Abstract: A method and mechanism for automatic or manual winding of a stator. A fixed arbor serves to support the stator during the winding process, as well as a wire feed point and wire guide. A mechanism moves the stator in a back and forth motion along the major axis of the arbor. Proper axial position of the wire is maintained by the outer surface of the arbor and the axial slot itself. The arbor has a channel that serves to guide the wire, allowing it exit in each of the two possible longitudinal directions along the major axis of the arbor.Type: GrantFiled: July 9, 2007Date of Patent: October 4, 2011Inventors: Robert M. Jones, Joseph M. Lisiecki
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Patent number: 8028398Abstract: A method of making a wound field for a brushless direct current motor, direct current generator, alternating current motor or alternating current generator, includes providing a base mold and a press mold. Next, a number of phases is determined. At least one strand of conductive material per phase is formed between the base mold and press mold into a conductive coil that has a shape that indicates the number of poles required. Each conductive coil is inserted into the stator core, and the stator core is installed into one of a brushless direct current motor, direct current generator, alternating current motor or alternating current generator.Type: GrantFiled: November 26, 2008Date of Patent: October 4, 2011Assignee: Yeadon Energy Systems, Inc.Inventor: William H. Yeadon
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Patent number: 8020423Abstract: An electronic casing and a method of manufacturing the same are provided. The method includes the following steps. Step (a): a metal laminate and a die of a predetermined shape are provided. The metal laminate comprises a metal top layer and a metal bottom layer that are bonded by interface atom diffusion. Step (b): the metal laminate is processed to form a casing blank by using the die, and the casing blank has at least one turning portion. Step (c): a profiler of a predetermined shape and an electromagnetic forming device are provided. Step (d): the casing blank is attached to the profiler, and the electromagnetic forming device is disposed at a position corresponding to the turning portion. Step (e): the electromagnetic forming device is activated, so that the casing blank has a shape corresponding to the predetermined shape of the profiler.Type: GrantFiled: December 20, 2007Date of Patent: September 20, 2011Assignee: Metal Industries Research & Development CentreInventors: Chih-Yuan Chen, Chun-Chieh Wang, Tzyy-Ker Sue, Chin-Chuan Huang, Chi-Keung Chung
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Publication number: 20110215891Abstract: An assembly includes a toroidal induction component, a potting cup, and potting material. The toroidal induction component includes a conductive winding, where at least ends of the conductive winding define a lead set of the toroidal induction component. The potting cup is configured to accept the toroidal induction component and its lead set. Techniques for forming the assembly are also described.Type: ApplicationFiled: March 3, 2010Publication date: September 8, 2011Applicant: Honeywell International Inc.Inventors: Lance L. Sundstrom, Wiclyff T. Bonga, Michael J. Gillespie
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Patent number: 8013697Abstract: A method of manufacturing a solenoidal magnet structure, includes the step of providing a collapsible accurate mold in which to wind the coils winding wire into defined positions in the mold, placing a mechanical support structure over the coils so wound, impregnating the coils and the mechanical support structure with a thermosetting resin, allowing the thermosetting resin to harden, and collapsing the mold and removing the resultant solenoidal magnet structure formed by the resin impregnated coils and the mechanical support structure from the mold as a single solid piece.Type: GrantFiled: January 22, 2009Date of Patent: September 6, 2011Assignee: Siemens PLCInventors: Simon James Calvert, Jonathan Noys, Adrian Mark Thomas
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Publication number: 20110209340Abstract: An apparatus, system, and method are disclosed for combining multiple windings on a magnetic core. An integrated winding structure has a winding base and multiple winding extensions. The multiple winding extensions and the winding base are formed from a single sheet of electrically conductive material. Each of the multiple winding extensions has a base portion that extends from the winding base, a wrapping portion that extends from the base portion, and a connection portion that extends from the wrapping portion. The connection portions and the winding base each have electrical connection surfaces. Each of the multiple winding extensions forms one or more windings on the magnetic core.Type: ApplicationFiled: May 9, 2011Publication date: September 1, 2011Applicant: INTERNATIONAL BUSINESS MACHINES CORPORATIONInventors: Chu T. Chung, Chien H. Lin, Randhir S. Malik, Robert Wei
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Patent number: 8006370Abstract: A method for sealing a housing includes providing a base plate of the housing with at least one opening; providing an electrical connection that extends through the base plate from an inner side to an outer side of the base plate; and applying a sealing compound into the opening from an outer side of the base plate in order to seal an interface between the base plate and the electrical connection.Type: GrantFiled: May 21, 2008Date of Patent: August 30, 2011Assignee: Tyco Electronics AMP GmbHInventors: Ralf Hoffmann, Alexander Linke, Martin Wieberger, Titus Ziegler
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Patent number: 8001672Abstract: A method for manufacture of a conductor assembly along a curvilinear axis. The assembly may be 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 one example, the assembly includes a structure having a curved shape extending along the axis. A surface of the structure is positioned for formation of a channel along the curved shape. The structure is rotated about a second axis. While rotating the structure, a channel is formed in the surface that results in a helical shape in the structure. The channel extends both around and along the first axis.Type: GrantFiled: June 5, 2008Date of Patent: August 23, 2011Assignee: Advanced Magnet Lab, IncInventor: Rainer Meinke
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Patent number: 8004379Abstract: A biased gap inductor includes a first ferromagnetic plate, a second ferromagnetic plate, a conductor sandwiched between the first ferromagnetic plate and the second ferromagnetic plate, and an adhesive between the first ferromagnetic plate and the second ferromagnetic plate, the adhesive comprising magnet powder to thereby form at least one magnetic gap. A method of forming an inductor includes providing a first ferromagnetic plate and a second ferromagnetic plate and a conductor, placing the conductor between the first ferromagnetic plate and the second ferromagnetic plate, adhering the first ferromagnetic plate to the second ferromagnetic plate with a composition comprising an adhesive and a magnet powder to form magnetic gaps, and magnetizing the inductor.Type: GrantFiled: June 6, 2008Date of Patent: August 23, 2011Assignee: Vishay Dale Electronics, Inc.Inventor: Thomas T. Hansen
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Patent number: 7996985Abstract: A method of making a relay includes: preparing a relay core member; coupling first, second and third terminals to the relay core member by moving the same horizontally relative to the relay core member such that terminal portions of the first, second and third terminals enter notches formed in the relay core member in a horizontal direction; and enclosing the relay core member, the first terminal, the second terminal, and the third terminal within a housing, and sealing the housing with resin.Type: GrantFiled: November 13, 2007Date of Patent: August 16, 2011Assignee: Excel Cell Electronic Co., LtdInventor: Ming-Chang Kuo
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Publication number: 20110192019Abstract: To provide a spool for a coil winding device capable of preventing poor insulation caused by a leakage of coil wires without initially inserted coil wires staying at the vicinity of slot openings. A spool for a coil winding device of this invention includes a plurality of coil winding surfaces increased stepwise in diameter from the bottom upward in a state where the spool is disposed on the coil winding device. The spool includes a front spool part and a rear spool part, which are placed at a distance from each other so that each turn of coil has a length corresponding to arbitrary lamination thickness of the stator core.Type: ApplicationFiled: September 2, 2008Publication date: August 11, 2011Applicant: Mitsubishi Electric CorporationInventors: Daisuke Shijo, Masaya Motogashi, Hiroyuki Akita, Toshio Arai
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Patent number: 7992284Abstract: 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.Type: GrantFiled: June 5, 2008Date of Patent: August 9, 2011Assignee: Advanced Magnet Lab, Inc.Inventor: Rainer Meinke
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Patent number: 7971341Abstract: 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.Type: GrantFiled: March 25, 2008Date of Patent: July 5, 2011Assignee: Medtronic Navigation, Inc.Inventors: John H. Dukesherer, Bruce M. Burg, Bradley A. Jascob, Paul Kessman
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Patent number: 7971342Abstract: A conductor assembly and method of manufacture. The assembly includes a magnetic coil positioned about a curvilinear axis with one or more coil rows comprising conductive material having an arcuate shape. A generated field is characterized by a dipole component having a first magnitude, a quadrupole component having a second magnitude, a sextupole component having a third magnitude and a decupole component having a fourth magnitude. The third and fourth magnitudes are each 10?3 the first magnitude or less.Type: GrantFiled: June 5, 2008Date of Patent: July 5, 2011Assignee: Advanced Magnet Lab, Inc.Inventor: Rainer Meinke
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Publication number: 20110148562Abstract: Disclosed is a field coil assembly of an electromagnetic clutch including a bobbin from which lead wires, which are both ends of a coil made of an aluminum-based material, protrude outward, a core that surrounds the bobbin such that the lead wires are exposed, a bobbin terminal installed at the bobbin while being adjacent to the lead wire of the coil, and a connector coupled to the core and including a lead wire terminal. The lead wires of the coil are connected to the bobbin terminal through heating and pressing.Type: ApplicationFiled: December 20, 2010Publication date: June 23, 2011Inventors: Sung-Taeg OH, Seong-Gyu Gong, Suk-Jae Chung, Seung-Kil Kim, Chung-Han Shin, Jong-Myung Seok, Dae-Yong Park
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Patent number: 7963025Abstract: A stator for an inner rotor type motor includes a stator core 1, insulating members 10 and winding wire 3, 4. The stator core 1 includes: four divisional core elements 6 each integrally formed by setting up one tooth 2 to one yoke portion 8; and four divisional yoke elements 7. A rotor opening 11 is formed on top portions of the teeth 2 by arranging the divisional core elements 6 so that the teeth 2 are radially disposed. Four slots 9 are formed by respectively arranging the divisional yoke elements 7 between the yoke portions 8 of the adjacent divisional core elements 6. The winding wire 3, 4 is wound on the teeth 2. An inner surface of each yoke portion 8 is substantially perpendicular to the central axis of the corresponding tooth 2 while the insulating member 10 is provided on side surfaces of each tooth 2.Type: GrantFiled: January 10, 2008Date of Patent: June 21, 2011Assignee: Matsushita Electric Industrial Co., Ltd.Inventor: Shigeki Nishimura
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Patent number: 7963021Abstract: An inductor embedded in a substrate, including a substrate, a coil electrode formed by filling a metal in a spiral hole formed on the substrate, an insulation layer formed on the substrate, and an external connection pad formed on the insulation layer to be connected to the coil electrode. The inductor-embedded substrate can be used as a cap for a micro device package by forming a cavity on its bottom surface.Type: GrantFiled: February 8, 2008Date of Patent: June 21, 2011Assignee: Samsung Electronics Co., Ltd.Inventors: Moon-chul Lee, Jong-oh Kwon, Woon-bae Kim, Jea-shik Shin, Jun-sik Hwang, Eun-sung Lee
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Patent number: 7961072Abstract: An inductive element comprises at least two core-parts including a magnetically permeable material and at least one winding of an electrical conductor which can be a foil winding, a stranded wire (litz) winding or a conventional wire winding. Each core-part has an elongated center piece with an outer winding surface. At each of its longitudinal ends, the center piece has a contact element with a lateral contact surface. The winding is wound directly on the core-parts without a bobbin or the-like. The core-parts of the inductive element are arranged with their longitudinal axes essentially in parallel in a manner that the lateral contact surfaces of each contact element abut on a lateral contact surface of another core-part. Such an inductive element can be manufactured by co-axially arranging the core-parts and using them as a roll-shaft. After the windings have been applied to the core-parts, they can be rearranged, i.e. “flipped over,” in a stack-like arrangement in order to form an inductive element.Type: GrantFiled: August 31, 2007Date of Patent: June 14, 2011Assignee: DET International Holding LimitedInventors: Jurgen Pilniak, Peter Wallmeier
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Patent number: 7956507Abstract: In a rotor for a rotating electrical machine, a flange of an insulating bobbin is formed with a first hook portion and a second hook portion. The first hook portion directs a lead of a field coil both against the winding direction of the field coil and radially inward. The first hook portion has a first groove in which is hooked a proximal portion of the lead. The second hook portion directs the lead axially outward. The second hook portion has a second groove which has an open end on a radially inner periphery of the second hook portion, a closed end positioned radially outward of the open end, and a neck between the open and closed ends. The second hook portion has an intermediate portion of the lead hooked in the second groove between the neck and closed end of the second groove.Type: GrantFiled: March 19, 2009Date of Patent: June 7, 2011Assignee: Denso CorporationInventor: Takashi Tokizawa
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Publication number: 20110128107Abstract: To provide a chip inductor, which can make magnetic loss of the inductor element reduced, excellent in electrical property such as high Q etc., and high reliability, which is demanded for use in vehicles. The chip inductor comprises a ferrite core (11) comprising an axial section (11a), flange portions (11b) disposed at both ends of the axial section, and concavities (11c) opened for direction of the axial section on at least one face of the flange section; an internal electrode (13) consisting of metallic plate having a notch portion at axial section side, the internal electrode fixed on the upper face of the flange section having the concavity; and a winding (12) wound around the axial section of the ferrite core; wherein an end portion of the winding (12a) comes in contact to a side of the concavity, which faces to the axial section, comes in contact to the notch portion of the internal electrode, and is fixed on upper face of the internal electrode.Type: ApplicationFiled: June 3, 2009Publication date: June 2, 2011Applicant: KOA CORPORATIONInventors: Masaki Kitagawa, Yukiko Ohta, Miho Kawasaki
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Patent number: 7952460Abstract: An electronic circuit has an inductor. The inductor comprises a first number of electrically conductive tracks (108, . . . ) in, or on, a substrate (105). The tracks are separated from one another. The inductor comprises a second number of electrically conductive wires (120, . . . ). The ends of each wire contacts two different ones of the tracks. Among the first number of tracks there is at least a specific track that is electrically isolated from the wires upon the wires having been connected. Such an inductor can be made using a standardized track configuration on a substrate, and selectively skipping one or more tracks in order to determine the inductance.Type: GrantFiled: October 29, 2007Date of Patent: May 31, 2011Assignee: NXP B.V.Inventors: Michael Joehren, Horst Roehm
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Publication number: 20110121935Abstract: A composite magnetic core assembly includes an inner magnetic core and an outer magnetic core. The inner magnetic core is made of a high saturation flux density and low permeability material. The outer magnetic core is made of a low saturation flux density and high permeability material. The outer magnetic core includes a ring-shaped wall and a receptacle. The inner magnetic core is accommodated within the receptacle.Type: ApplicationFiled: November 22, 2010Publication date: May 26, 2011Applicant: DELTA ELECTRONICS, INC.Inventors: Jiang Chu, Wei Chen, I-Chi Cheng, Yi-Fan Wu, Zhi Huang
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Patent number: 7948142Abstract: A rotor provided in rotary electric machines comprises a stator core having a radial direction and slots provided with bottomed openings directed in the radial direction. The rotor also comprises a stator coil comprising slot accommodation portions being accommodated in the slots of the stator core and coil end portions each connecting mutually adjacent slot accommodation portions among the slot accommodation portions and respectively protruding from both end faces of the stator core. The stator coil is pre-formed into a cylindrical shape before the slot accommodation portions are accommodated into the slots of the stator core. The slot accommodation portions are formed to respectively have convex parts each protruding toward an opposite way to the slot openings, before the slot accommodation portions are accommodated into the slots. The convex parts are pressed by the stator core toward the openings during accommodation of the slot accommodation portions into the slots.Type: GrantFiled: April 23, 2009Date of Patent: May 24, 2011Assignee: Denso CorporationInventors: Masaomi Dobashi, Akito Akimoto, Yoshinobu Yanagisawa
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Publication number: 20110095754Abstract: A method for manufacturing a field sensor including a series of n probes, in which n>=3, each formed of a core of magnetic alloys associated with a coil. According to the invention, the method includes the steps of ensuring the deposit of cores of magnetic alloys onto a non-magnetic substrate, on at least part or the entirety of a surface corresponding to a series of n strips extending along axes (x, y, z) concurrent at an intersection and connected by an intersection region (z), before or after this deposit, cutting out the n strips in the substrate leaving them connected to the substrate by at least one attachment, assembling each strip with a coil, and folding at least one strip along a fold line perpendicular to the axis thereof.Type: ApplicationFiled: February 25, 2009Publication date: April 28, 2011Applicants: UNIVERSITE CLAUDE BERNARD LYON I, CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE, ARCELORMITTAL- STAINLESS & NICKEL ALLOYSInventors: Laurent Morel, Jean-Pierre Reyal
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Patent number: 7930818Abstract: In a stator mounting method in which a coil unit is inserted into a stator core and a lead wire protruding from the coil unit is inserted into and mounted on a terminal portion of the stator core, the lead wire is passed through a lead wire pullout portion located at a predetermined position of a coil frame body, a height from an inner peripheral upper face of the coil frame body to the lead wire pullout portion is equalized with a distance from a core upper face of the stator core to a lead wire insertion position inner peripheral lower face of the terminal portion, and the core upper face of the stator core is held in contact with an inner peripheral upper face of the coil frame body after the lead wire is inserted into the terminal portion.Type: GrantFiled: March 10, 2009Date of Patent: April 26, 2011Assignee: Toyota Jidosha Kabushiki KaishaInventor: Yasuyuki Hirao
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Patent number: 7926168Abstract: A method of manufacturing a coil having a cross section differing from a circular ring cross section. In this method a circular cylindrical coil with a circular ring cross section is first wound and then reshaped into a coil with a cross section differing from the circular ring cross section. At least two axially parallel fingers of an expander are temporarily inserted into the coil interior for reshaping the wound circular cylindrical coil and are displaced in a diverging relative movement after the insertion and while doing so expand the initially circular cylindrical coil into the coil having the different cross section.Type: GrantFiled: August 16, 2005Date of Patent: April 19, 2011Assignee: NXP B.V.Inventor: Heinz Nierlich
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Patent number: 7924123Abstract: An electromagnetic relay has a solenoid formed from a wound coil, a movable contact-point block having a movable iron core, an insulation holder integrated with the upper end portion of the movable iron core and a movable contact piece which is biased toward and supported by the insulation holder through a contact pressing spring, and a fixed iron core fitted in a through hole in a yoke. A restoring spring is inserted into an axial hole of the solenoid. The movable iron core of the movable contact-point block is slidably inserted into the axial hole of the solenoid from thereabove. The fixed iron core is inserted into the axial hole from therebelow. The movable iron core is adapted to be slid into the axial hole based on the magnetization force and the demagnetization of the coil to move the movable contact-point block back and forth.Type: GrantFiled: May 11, 2007Date of Patent: April 12, 2011Assignee: OMRON CorporationInventors: Keisuke Yano, Masayuki Noda, Hiroshi Ono, Hiroyuki Fujita
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Patent number: 7921546Abstract: A method for making a high current low profile inductor includes forming an inductor element comprising a coil having an open center and an outside surface, the coil also having first and second coil ends, making a dry mixture comprising a dry resin and an insulated dry powdered magnetic powder, and compressing the dry mixture around the outside surface of the coil and within the open center of the coil to create an inductor body without liquefying the dry mixture, whereby the inductor body engages the coil both within the coil open center and also the coil outside surface.Type: GrantFiled: January 14, 2008Date of Patent: April 12, 2011Assignee: Vishay Dale Electronics, Inc.Inventors: Timothy M. Shafer, Brett W. Jelkin
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Patent number: 7921545Abstract: Stator coils are retained by an inserting blade and a setting blade. The setting blade is rotated in this state. Then, after rotation, the stator coils are set on the inserting blade. At this time, the stator coils are arranged in the inserting blade in a state where the stator coils overlap one another to form a spiral shape. Thus, the stator coils are arranged uniformly.Type: GrantFiled: May 11, 2007Date of Patent: April 12, 2011Assignee: Kabushiki Kaisha Toyota JidoshokkiInventor: Kazuyuki Yamaguchi
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Publication number: 20110074532Abstract: A cost effective integrated automotive solution for a charger transformer with minimized fringing flux and core grounding for reducing electromagnetic interference (EMI). The method provides an air gap filled with a mixture of an adhesive and ferrite powder that bonds the ferrite core sections together. In addition, the ground pin of the transformer is exposed through a groove in the pocket of the bobbin on which the core is mounted and an electrical contact is established between the exposed end of the ground pin and the core surface by means of a drop of epoxy.Type: ApplicationFiled: September 30, 2009Publication date: March 31, 2011Applicant: Astec International LimitedInventors: Wo Oi Cheng, Alfredo Grueso
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Patent number: 7913376Abstract: A method of forming an actuating mechanism for a probe storage system includes providing a scanner chip having a main body including first and second outer surfaces and first and second coil mounting cavities. First and second coils are positioned in respective ones of the first and second coil mounting cavities. First and second magnet receiving pockets are formed in a first plate with first and second magnets being positioned in corresponding ones of the first and second magnet receiving pockets. The first plate is arranged relative to one of the first and second outer surfaces of the scanner chip with the first and second magnets registering with respective ones of the first and second coils. The first plate is spaced from the one of the first and second outer surfaces by a gap of less than about 10 microns.Type: GrantFiled: December 13, 2007Date of Patent: March 29, 2011Assignee: International Business Machines CorporationInventors: Mark A. Lantz, Hugo E. Rothuizen
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Patent number: 7915781Abstract: In a stator winding method for winding conductive wires 8 around teeth 4a to 4f of a stator core 4 having 3n teeth 4a to 4f and 3n slots 5a to 5f by use of a bobbin machine 12 having three nozzles 13, the slots 5a to 5f on both sides of the teeth 4a, 4d, 4f in the nth winding process are formed, in respective slot portions on the side of the teeth 4a, 4d, 4f in the nth winding process, so that respective depths “A” are all smaller than respective depths “B” of the remaining portions. At the final stage of the nth winding process, the nozzles 13 are moved from the interior side of the slots 5a to 5f toward the inner circumferential side of the stator core 3 and furthermore, the conductive wires 8 are wound around the teeth 4b, 4d, 4f so that each gap 14 between the conductive wires 8 wound around the teeth 4b, 4d, 4f and the conductive wires 8 wound around the teeth 4a, 4c, 4e is smaller than an outer diameter of the nozzle 13.Type: GrantFiled: December 19, 2007Date of Patent: March 29, 2011Assignee: Toshiba Carrier CorporationInventor: Toshihiko Futami
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Patent number: 7905009Abstract: A method of forming a transformer coil, wherein first and second fibrous layers are provided. Each of the first and second fibrous layers includes a fabric formed from a plurality of interconnected fibers and a plurality of spacers affixed to the fabric and protruding therefrom. A conductor layer is disposed over the first fibrous layer such that a first side of the conductor layer contacts the spacers of the first fibrous layer. The second fibrous layer is disposed over the conductor layer such that a second side of the conductor layer contacts the spacers of the second fibrous layer. A resin is applied so as to cover the conductor layer and the first and second fibrous layers.Type: GrantFiled: May 24, 2007Date of Patent: March 15, 2011Assignee: ABB Technology AGInventors: William E. Pauley, Jr., Rush Horton, Jr., Charlie H. Sarver, Curtis H. Frye
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Patent number: 7905008Abstract: There is provided a method of manufacturing a coil component, where a first insulation layer is formed on a first magnetic substrate, an insulation film is formed on the first insulation layer, a coil conductor is formed on the insulation film, another insulation film is formed on the coil conductor, and an open region is formed on the inner circumference side and on the outer circumference side of the coil conductor. A magnetic later is embedded, at least partially, in the open region, and a second magnetic substrate is secured on the magnetic layer. Also, a plurality of electrode terminals are formed, where one of the electrode terminals is connected to a terminal portion of the coil conductor, and the electrode terminals are provided across sides of the first and second magnetic substrates. Therefore, the first insulation layer can suitably prevent shorting failures between the electrode terminals.Type: GrantFiled: October 24, 2006Date of Patent: March 15, 2011Assignee: TDK CorporationInventors: Makoto Yoshida, Nobuyuki Okuzawa, Tomokazu Ito, Takashi Kudo, Makoto Otomo, Akira Sato
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Patent number: 7900343Abstract: A group of magnetic strands are configured into a minimal number of solid magnetized toroidal rings with a conical magnetization direction and then aligned, stacked and assembled into a magic sphere magnetic structure. Each magnetized toroidal ring has predetermined dimensions to form the inner and outer surfaces of a spherical shell. The present invention also encompasses a magic sphere magnetic device with unsegmented solid magnetized toroidal rings and methods for assembling a magic sphere by stacking magnetized toroidal rings with a conical magnetic direction.Type: GrantFiled: May 20, 2008Date of Patent: March 8, 2011Assignee: The United States of America as represented by the Secretary of the ArmyInventor: Herbert A. Leupold
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Publication number: 20110043315Abstract: The transformer includes a bobbin, a plurality of terminal electrode, a primary coil, a secondary coil, and a hook part. The bobbin includes a core portion extending in an axial direction, and terminal bases fixed at both ends of the core portion in the axial direction. The plurality of terminal electrode regions is provided on the terminal bases. Each terminal electrode region is provided with a wire connection part. The primary coil comprises a plurality of primary wires. The secondary coil comprises a plurality of secondary wires. The hook part is disposed between the core portion and one of the terminal electrode regions and configured to hook at least one of the primary wires and the secondary wires.Type: ApplicationFiled: August 19, 2010Publication date: February 24, 2011Applicant: TDK CORPORATIONInventors: Katsumi KOBAYASHI, Yutaka HATAKEYAMA, Makoto ONO
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Patent number: 7891082Abstract: A method of manufacturing a coil assembly unit comprises steps of coil forming, weaving, compressing steps. In the forming step, each coil wire is formed which provides linear portions and turn portions each connecting linear portions, during which bent portions are formed at both ends of each linear portion, the bent portions being bent so that mutually adjacent linear portions are deviated from each other. In the weaving step, the coil wires are mutually woven in turn, in which the turn portions intersect in turn. All the coil wires are subjected to the weaving step in turn to produce a woven coil assembly. In the compressing step, the woven coil assembly is compressed by compressing the woven coil so that each bent portion is deformed to be linear to allow the mutually adjacent linear portions to come closer to each other, thus producing the coil assembly unit.Type: GrantFiled: April 21, 2009Date of Patent: February 22, 2011Assignee: Denso CorporationInventor: Akito Akimoto
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Patent number: 7886425Abstract: A method of manufacturing a transformer is disclosed. A first bobbin piece, having a first channel and a primary winding section is provided. A second bobbin comprising first and second secondary side plates, plural partition plates, a wall portion, a secondary base having a first pin arranged on a bottom surface of the secondary base, plural secondary winding sections, and a second channel is provided. A second pin is inserted into the second bobbin piece to form a wire-arranging part protruded from the second secondary side plate and an insertion part protruded from the bottom surface of the secondary base. A primary winding coil is wound on the primary winding section, and the first and second terminals of a secondary winding coil are respectively fixed on the first pin and the wire-arranging part. A magnetic core assembly is partially disposed within the first channel and the second channel.Type: GrantFiled: November 20, 2008Date of Patent: February 15, 2011Assignee: Delta Electronics, Inc.Inventors: Tzu-Yang Liu, Ching-Hsien Teng, Hsin-Wei Tsai, Yi-Lin Chen, Bou-Jun Zung, Chia-Hung Pai, Shih-Hsien Chang
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Patent number: 7882619Abstract: Stator coils are inclined with respect to the axial direction of annularly arranged coil holding portions and such that at least parts of the stator coils overlap one another. In setting the stator coils on the coil holder, the stator coils are sequentially set on the coil holder in a predetermined direction, which is a coil setting direction, from the starting stator coil so as to overlap one another. The second section of the ending stator coil is set at the same position as a position where the first section of the starting stator coil is set in the circumferential direction or at a position advanced from the position where the first section of the starting stator coil is set in the circumferential direction. The ending stator coil is set on the coil holder to be further inward than the starting stator coil. Therefore, stator coils are evenly arranged.Type: GrantFiled: June 14, 2007Date of Patent: February 8, 2011Assignee: Kabushiki Kaisha Toyota JidoshokkiInventors: Kazuyuki Yamaguchi, Tetsuya Koyama, Yusuke Niimi, Kenji Yoshida
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Patent number: 7882615Abstract: The present invention is directed to a method of forming a transformer having a stacked core, which includes upper and lower yokes and first and second outer legs. The core also includes one or more inner legs. Each of the upper and lower yokes is formed from a stack of plates and has a rectangular cross-section. Each inner leg is formed from a stack of plates and has a cruciform cross-section. Each of the first and second outer legs is formed from a stack of plates and may have a cruciform cross-section.Type: GrantFiled: July 18, 2007Date of Patent: February 8, 2011Assignee: ABB Technology AGInventors: William E. Pauley, Jr., Charlie H. Sarver, Rush B. Horton, Jr.
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Patent number: 7882614Abstract: A method for providing a power inductor comprises forming a first magnetic core material having first and second ends and an inner cavity that extends from the first end to the second end; forming a first notch in the first magnetic core material that projects inwardly towards the inner cavity from one of the first and second ends; and passing a first conductor through the inner cavity that is received by the first notch.Type: GrantFiled: March 3, 2006Date of Patent: February 8, 2011Assignee: Marvell World Trade Ltd.Inventor: Sehat Sutardja
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Publication number: 20110025446Abstract: An apparatus for effecting inductive coupling among a plurality of electrical elements includes: (a) an electrically non-conductive core member oriented about an axis; (b) at least one first electrical element of the plurality of electrical elements substantially nestingly surrounding the core member oriented about the axis; each respective first electrical element being in spaced relation vis-à-vis other first electrical elements in an installed orientation; and (c) at least one second electrical element of the plurality of electrical elements disposed in surrounding relation with respect to the core member about the axis sufficiently proximal with at least one selected said first electrical element in the installed orientation to establish the inductive coupling.Type: ApplicationFiled: August 3, 2009Publication date: February 3, 2011Applicant: Lineage Power Corporation, a Corp. of NevadaInventors: Robert James Catalano, Roger Dale Grandchampt, William Lonzo Woods, JR.