Abstract: A common mode filter comprises an insulating substrate, a lower coil leading layer, a coil main body multilayer, and an upper coil leading layer. The upper coil leading layer comprises at least one upper lead, at least one upper terminal, and at least one upper contact, and the lower coil leading layer comprises at least one lower lead, at least one lower terminal, and at least one lower contact. The two ends of the upper lead are respectively connected to the upper terminal and the upper contact, and the upper lead surrounds the upper contact. The two ends of the lower lead are respectively connected to the lower terminal and the lower contact, and the lower lead surrounds the lower contact. The upper coil leading layer and the lower coil leading layer sandwich the coil main body multi-layer, and the lower coil leading layer is disposed on the insulating substrate.

Abstract: The present invention is directed to a method of making a transformer having a stacked core, which includes top and bottom yokes and first and second outer legs. The core also includes an inner leg that is formed from a pair of stacked plates, which abut each along a seam that extends in the longitudinal direction of the inner leg. Each of the upper and lower yokes may be formed from a single stack of plates, or a plurality of stacks of plates. Each of the inner and outer legs may also be formed from a single stack of plates, or a plurality of stacks of plates. The cross-section of the core may be rectangular or cruciform.

Abstract: A variable inductor is provided. The variable inductor includes a dielectric core having a helical thread on an outer surface thereof for receiving the coil, and a non-magnetic element positioned coaxially within the core. The non-magnetic element could be provided in the form of a bushing or a solid rod, and could be manufactured from any suitable, non-magnetic metal, such as copper, brass, etc.

Abstract: An electronic component includes a multilayer composite including first insulating layers, second insulating layers, and a helical coil. The helical coil is disposed within the multilayer composite and includes a plurality of coil conductors connected to each other with a plurality of via hole conductors. The coil is located corresponding to the region defined by the second insulating layers when viewed in a stacking direction of the first and second insulating layers. The second insulating layers are located in the region coinciding with the locus of the coil without covering the via hole conductors when viewed in the stacking direction.

Abstract: There is provided a transformer and a method of manufacturing the same. The transformer includes a bobbin wound with coils; cores having center leg parts inserted from both ends of the bobbin and contacting each other; and a shielding member preventing an inflow of an impregnant into the center leg parts inside the bobbin during a varnish impregnation of the cores.

Abstract: A method is disclosed for producing a pole face of a metal closing elements of a solenoid, especially for electromechanical switchgear. In at least one embodiment, the method includes machining the surface of a crude stamped part of the closing element to give the pole face. A corresponding armature, yoke, solenoid and switchgear are also disclosed.

Abstract: A current transformer core has a ratio of the core outside diameter Da to the core inside diameter Di of <1.5, a saturation magnetostriction ?s of =|4| ppm, a circular hysteresis loop with 0.50=Br/Bs=0.85 and an Hcmax=20 mA/cm. The current transformer core is made of a soft magnetic iron alloy in which at least 50% of the alloy structure is occupied by fine-crystalline particles with an average particle size of 100 nm or less, and the iron-based alloy comprises, in essence, one combination.

Abstract: 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.

Abstract: An electric motor that does not provide new terminals for carrying out conductive caulking, and further, facilitates the work of using a conductive caulking machine. An electric motor coil connecting structure that connects conductors connected to a power input member and lead terminals of coils by conductive caulking and connects the power input member and the lead terminals of the coil electrically. One end of each of the conductors is formed into a terminal-shaped portion in which the lead terminals of the coil can be fitted and temporarily retained. The lead terminals of the coil are fitted in the terminal-shaped portion of the conductors and temporarily retained, and connected by conductive caulking.

Abstract: A method for making a power inductor comprises providing a first magnetic core comprising a ferrite bead core material, cutting a first cavity and a first air gap in said first magnetic core, and attaching a second magnetic core to said first magnetic core at least one of in and adjacent to said air gap.

Abstract: A planar transformer or balun device, having small trace spacing and high mutual coupling coefficient, and a method of fabricating the same is disclosed. The method may comprise providing a first and a second inductor on a primary and a second substrate respectively, interleaving at least partially the first inductor with the second inductor, coupling the primary and the secondary substrates to form a unitary structure, and providing electrical contacts to couple the first and second inductors with another device or circuit.

Abstract: A method for producing a winding, particularly for electrical transformer from a cylindrical tubular metal element of polygonal cross-section, includes steps of machining, in a first series of passes, a first series of cuts substantially parallel to one another through all of the sides of the tubular element with the exception of a last one of said sides, and machining, in a second series of passes, a second series of cuts in said last one of said sides in order to ensure that junctions of the first series of cuts open out in the sides adjacent to the second series of cuts, so that the first and second series of cuts are continuous with respect to one another and constitute a single groove of helicoidal shape.

Abstract: A method of fabricating a coil-embedded inductor provides steps for obtaining uniform density of coil-embedded inductor. The cavity of a first die is filled with dust before being flipped, and then filled with dust a second time. The dust in the cavity is pressed only once for improving the density.

Abstract: A solenoid device includes a solenoid assembly (30) including a stator (42, 32, 38), a coil (36) for generating a magnetic field, and first retention structure (64). Armature and seal assembly includes armature structure (14, 16) that moves with respect to the solenoid assembly from a closed position to an open position in response to the magnetic field generated by the coil, seal structure (22) that is coupled with a proximal end of the armature structure and has a sealing edge (28) to seal with a component when the armature structure is in the closed position thereof, and second retention structure (68). A spring (44) biases the armature structure to the closed position. The first and second retention structures engage and retain the armature and seal assembly with respect to the stafor assembly prior to installation of the device.

Abstract: The present invention is intended as a method for producing an electromagnetic transducer of variable reluctance type, where the transducer's seismic mass side and load side are mounted together in a first step while the inner and/or outer air gaps are supplied with shims in order to create balanced air gaps in an axial direction between the bobbin core's arms and the inner and outer yokes, whereupon in a second step the bobbin core is fixed through the side piece to an adapter already attached in a corresponding free moving end of a spring suspension, with compliant properties working in an axial direction and arranged between the seismic mass side and the load side in resting state in order to maintain balanced air gaps when finally, in a third step, the shims are removed and the air gaps are released.

Abstract: In a stator for an automotive alternator, the inner circumferential surfaces of the bridge portions are placed in contact with the end surfaces of the stator core without any gaps so that the spatial ratio occupied by the clusters of stator windings belonging to the bridge portions in the coil ends of the stator coil is at high density. The method of manufacture comprises a step of manufacturing a parallelepiped laminated body having a plurality of slots by laminating a plurality of comb-shaped strips each having a band portion and a plurality of teeth, a step of inserting into the slots from the side of the openings of the slots a stator coil comprising bridge portions and axially parallel portions having current generating portions, a step of extending the ends of the teeth of the laminated body in the longitudinal direction of the laminated body, and a step of bending the laminated body to form a cylindrical shape.

Abstract: Magnetic component assemblies including layered moldable magnetic materials and coils are advantageously utilized in providing surface mount magnetic components such as inductors and transformers.

Abstract: Magnetic component assemblies including moldable magnetic materials including surface mount termination features, as well as manufacturing methods therefor, are disclosed that are advantageously utilized in providing surface mount magnetic components such as inductors and transformers.

Abstract: An open magnetic circuit multilayer coil component includes a laminate with magnetic layers, a coil, and a nonmagnetic layer provided within the laminate so as to cross a magnetic path formed by energization of the coil. A nonmagnetic material constituting the nonmagnetic layer is a Zn—Cu-based ferrite nonmagnetic material, and a magnetic material constituting the magnetic layer is a magnetic material containing 100 parts by weight of an Ni—Zn—Cu-based magnetic ferrite material and 0.1 to 2.0 parts by weight, in terms of Co3O4, of Co added to the Ni—Zn—Cu-based magnetic ferrite material.

Abstract: An inductive component for a DC/DC converter is made by transferring a copper track (2) from a copper substrate (1) to a first ferrite plate (3). A second ferrite plate (5) is attached by glue to the first ferrite plate so that the track (2) forms an inductor coil sandwiched between the two ferrite plates (3,5). One of the plates has holes (4) in registration with the terminals of the coil, and these holes are filled with solder (5) to provide externally accessible contacts.

Abstract: A method of forming a power tool includes forming and balancing an armature by securing a lamination stack having slots therein on an armature shaft securing a commutator on one end of the armature shaft, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, and molding plastic to at least partially encase the magnet wires in plastic and forming a balancing feature. Plastic is removed from the balancing feature during dynamic balancing of the armature. The armature is then disposed in a stator to form an electric motor and the electric motor is disposed in a power tool.

Abstract: There is provided a tape core wire manufacturing apparatus that makes it possible to manufacture a large variety of tape core wires in small quantities with ease, and in addition, makes it easy to apply a uniform coating over a broad width. In the tape core wire manufacturing apparatus of the present invention, a coating apparatus that applies a coating material to respective optical fiber core wires has a coating head that moves in the longitudinal direction relatively to the respective optical fiber core wires that have been placed in a row on a coating jig. The coating head has a position adjustment surface that is located in the vicinity of a coating member of the coating head and adjusts the positioning in the thickness direction of the respective optical fiber core wires when these are in the form of a tape. This position adjustment surface is pressed against the respective optical fiber core wires. The coating head is also able to be tilted in the longitudinal direction.

Abstract: A method of making a wound field for a brushless direct current motor, direct current generator, alternating current motor or alternating current generator, includes steps of providing a base mold and a press mold. Another step comprises determining a number of phases. 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.

Abstract: Low profile magnetic components and methods of manufacture include first and second core pieces extending interior and exterior to an open center area of a coil. Surface mount terminations are also provided to complete electrical connections to a circuit board.

Abstract: A washing machine with a direct drive motor system including a tub, a drum rotatably mounted inside the tub, a shaft connected to the drum, and a direct drive motor comprising a rotor assembly fastened to the shaft and including magnets positioned in a circumferential direction, and a stator assembly. The stator assembly includes a plurality of magnetic cores and a disc-shaped element including a plurality of finger-shaped portions. Each of the finger-shaped portions has one of the plurality of magnetic cores secured thereto.

Abstract: The invention relates to an electric synchronous machine. There is a need for a dual rotor electric synchronous machine which has a mechanism for adjusting the rotor relative angular displacement while the machine is running in order to reduce back EMF. There is a need for such an adjusting mechanism which can carry high torque loads. An electric synchronous machine is provided with a housing, first and second shafts rotatably supported in the housing, each with a corresponding rotor fixed thereon, both having permanent magnet field poles. Each rotor is surrounded by a corresponding annular stator, and stator coils are wound through both stators. A planetary transmission is coupled between the first and second shafts and operable during rotation of the first and second shafts to adjust an angular orientation of the second shaft with respect to the first shaft.

Abstract: An inductor device includes a first magnetic body pattern layer in which slits are provided and which is made to a pattern, a lower insulating layer formed on the first magnetic body pattern layer, a planar coil layer formed on the lower insulating layer, an upper insulating layer formed on the planar coil layer, and a second magnetic body pattern layer formed on the upper insulating layer and in which slits are provided and which is made to a pattern, wherein the first magnetic body pattern layer and the second magnetic body pattern layer are arranged to intersect orthogonally with the planar coil layer.

Abstract: An electrical current sensor is disclosed having conducting coil portion and an insulating body portion, the conducting coil portion comprising a coil portion with one or more helical windings made of a wire conductor and encircling a central cavity. Adjacent windings are separated by a dielectrically effective gap, wherein the insulating body portion comprises a dielectric spacer comprising a helical gap maintaining protuberance configured for insertion in the central cavity of the windings such that the gap maintaining protuberance is at least partially inserted in the gap between windings.

Abstract: A electromagnetic relay in which bad electrical contact and failure of operation are prevented even when shavings are produced while an iron core is press-fitted into and mounted on a base. The electromagnetic relay includes an electromagnetic block supported by press-fitting both ends of an iron core of the electromagnetic block into an upper surface of a base and open or close a contact by a movable iron piece rotated by magnetization or demagnetization of the iron core with a coil, where shaving receptacles are made by forming separating ribs adjacent to at least one side of press-fit projections that are formed in press-fit concave portions provided on the upper surface of the base.

Abstract: A transformer and a method of manufacturing the same are provided. The transformer includes a coil assembly mounted to a leg of a core. The coil assembly includes a low voltage coil and an insulation spool disposed over the low voltage coil. The insulation spool is composed of an insulating material and includes a plurality of guide strips defining a plurality of series of aligned notches. A high voltage coil is mounted to the insulation spool and includes a plurality of disc windings disposed in the series of aligned notches, respectively. Each of the disc windings comprises alternating concentric conductor layers and insulating layers. The conductor layers each have a width to thickness ratio of greater than 20:1.

Abstract: An inductance component is disclosed. This inductance component includes base made of insulating material, coil section buried in base, and external electrode terminals electrically coupled to the ends of coil section. Stress buffering section is provided on the exposed interface between base and external electrode terminals, and this stress buffering section can ease the stress produced by the difference in thermal coefficients due to temperature changes. The foregoing structure thus allows improving the reliability of the inductance component with respect to a thermal shock.

Abstract: A forming machine for forming a loop winding having a plurality of meandering parts and disposed in a stator of a motor which includes: a first die unit having a plurality of first dies spaced from each other at regular intervals in a circumferential direction; and a second die unit having a plurality of second dies which are spaced from each other at the same intervals as the regular intervals in a circumferential direction and which are each disposed between adjacent ones of the first dies, wherein each of the second dies has a winding holding part for holding a loop winding; and the first die unit and the second die unit are each provided with a winding diameter reducing means for reducing the loop winding in the radial direction thereof according to a displacement of the first die unit in the axial direction relative to the loop winding held by the winding holding parts.

Abstract: A low cost, high performance inductive device for use in, e.g. electronic circuits is disclosed. In one exemplary embodiment, the device includes a two-legged magnetically permeable core optimized for fitting with one or more windings. Preferably, the device is also self-leaded, thereby simplifying its installation and mating to a parent device (e.g., PCB). In another embodiment, one or more low profile magnetically permeable cores are mounted on a surface of the self-leaded magnetically permeable core, preferably with a gap. In yet another embodiment, the aforementioned gap is obviated. In yet another embodiment, spacers are positioned on a surface of the self-leaded magnetically permeable core device to position the low profile magnetically permeable at a predetermined distance from the self-leaded magnetically permeable core. In yet another embodiment, a bead inductor is disclosed comprising a plurality of turns. Methods for manufacturing and utilizing the devices are also disclosed.

Abstract: In a method to produce a curved coil, in particular a sub-coil of a gradient coil for a magnetic resonance apparatus, at least one conductor is wound corresponding to a predetermined pattern on a winding plate, and a winding plate composed of multiple plate elements that are moveable relative to one another is used that is formed into a curved shape after the winding of the conductor, in which curved shape the conductor is fixed while maintaining the curved shape.

Abstract: Stator designs have wide-mouth slots between adjacent poles. Wire coils with high slot fill conductivity are formed around the poles. In some designs, the wire coils are wave wound around the poles. Thick bar conductors can be used for making the wire coils. The wire coils may be inserted using nozzle dispensers or transferred from a pre-form mandrel. In other designs, the wire coils are pre-formed on transferable pockets that are then mounted on the poles. Optional pole extensions or shoes can be attached to the stator poles after the wire coils are formed around the poles.

Abstract: In one embodiment, an inductance element includes a toroidal core and a bottomed insulating resin case. The bottomed insulating resin case includes a cylindrical outer wall section, a cylindrical inner wall section, a bottom section, an open section and a hollow section. The cylindrical outer wall section has an extending section exceeding the height of the toroidal core. The open section of the insulating resin case is covered with a cover portion having a bent section formed by bending an extending section of the cylindrical outer wall section.

Abstract: The invention is directed to a transformer and a method of manufacturing the same, wherein at least a portion of a core is disposed inside a shield case formed from a polymeric resin composition containing conductive particles. An encasement comprising a dielectric resin encapsulates the shield case. An electrical conductor is electrically connected to the shield case and is accessible from the exterior of the encasement.

Abstract: A method for manufacturing multiphase windings (32) of an electric machine provides the following process steps: Cross-sectional profiles (13) that increase the slot space factor are stamped onto wire elements (7, 11, 12). Offsetting dies (14, 26) are loaded with stamped wire elements (7) to constitute the winding (32), stamped wire elements (11) to constitute an integrated star point (21), and stamped wire elements (12) for supplying current to the winding (32). The offsetting dies (14, 26) offset the stamped wire elements (7, 11, 12) in their end regions. An interconnection of the integrated star point (21) is produced by thermally attaching (30) the stamped wire elements (11) for the integrated star point (21) to a connecting ring (40) on an inside (41) of a finished winding head (20).

Abstract: A manufacturing method of a winding assembly of a rotating electrical machine using a rotation block and a fixed block and a manufacturing apparatus used for the same. The rotation block includes a rotation surface rotatable around a rotation axis, and the fixed block includes a first surface and a second surface opposite to each other and a shaping surface. The shaping surface is formed between end parts of the first and the second surfaces, is made to have an almost semicircular shape with the rotation axis as the center, and extends along the rotation axis. Plural wire rods are simultaneously fed from the first surface of the fixed block to the rotation surface of the rotation block, and the wire rods positioned on the rotation surface are bent by rotation of the rotation block.

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: A compact inductor comprises a coil, a coil-burying body, and a body for a closed magnetic circuit. The coil-burying body is a fired porous ceramic body having a first magnetic permeability, in which the coil is buried. In the coil-burying body, “a through-hole 12a passing through inside of the coil along an axis of the coil” is formed. The body for a closed magnetic circuit is a fired dense ceramic body having a second magnetic permeability greater than the first magnetic permeability. The body for a closed magnetic circuit is arranged closely/densely at an outer circumference portion of the coil-burying body and in the through-hole. A magnetic path is therefore formed mainly within the body for a closed magnetic circuit, and the magnetic flux density is reduced in an area close to the coil. Accordingly, an inductor having the excellent superimposed DC current characteristic is provided.

Abstract: In a method for manufacturing a powder magnetic core, magnetic layer green sheets is formed by using magnetic metal particles having an insulating oxide layer on a surface thereof, and insulating layer green sheets are formed by using insulating particles. The magnetic layer green sheet and the insulating layer green sheet are alternately laminated, and the layers are press molded.

Abstract: A method of providing axially alternating N and S poles in a portion of an axially extending, cylindrical, smooth shaft for a linear stepper motor and a method of manufacturing a magnetizing fixture are provided. A magnetizing fixture is provided including a hollow cylindrical mandrel formed from a non-magnetic material, a single conductive wire serially disposed in parallel, circumferential channels defined in an outer surface of the mandrel, and a central bore defined axially and centrally through the mandrel. The portion of the shaft is inserted in the central bore and a direct current is provided through the wire to magnetize alternating N and S poles along the cylindrical shaft. The wire may be placed in the parallel, circumferential channels such that the direction of flow of a direct current in one channel is in the opposite direction of the flow in the adjacent channels.

Abstract: The invention relates to a laying vehicle for laying electric lines (8) in the grooves (6) of an inductor (4), for example a longitudinal stator of a maglev railway. The laying vehicle contains a first, preceding vehicle part (11) comprising a bending and offset unit (14) for configuring winding undulations, a second following vehicle part (16) comprising a pressing station (18) for pressing limbs (8a) of the undulations into the grooves (6), the second vehicle part (16) being displaceable in relation to the first vehicle part (11) and a slide (15) that is coupled in a driven manner to the first vehicle part (11), for transferring the undulations to the second vehicle part (16). According to the invention, a delivery unit (27), which is coupled to the second vehicle part (16), is located between the slide (15) and the pressing station (18), said unit receiving the limbs (8a) from the slide (15) and transferring them to the pressing station (18) at essentially constant intervals.

Abstract: A magnetic component and a method for manufacturing a low profile, magnetic component. The method comprises the steps of providing at least one sheet, coupling at least a portion of at least one winding to the at least one sheet, and laminating the at least one sheet with at least a portion of the at least one winding. The magnetic component comprises at least one sheet and at least a portion of at least one winding coupled to the at least one sheet, wherein the at least one sheet is laminated to at least a portion of the at least one winding. The winding may comprise a clip, a preformed coil, a stamped conductive foil, or an etched trace using chemical or laser etching. The sheet may comprise any material capable of being laminated and/or rolled, including, but not limited to, flexible magnetic powder sheets.

Abstract: A semiconductor device and fabricating method thereof are provided. A first substrate with an inductor cell and a through-electrode is connected to a second substrate having an RF device circuit unit. The first substrate can be stacked on the second substrate, and a connecting electrode can electrically connect the inductor cell to the RF device circuit unit.

Abstract: A method of manufacturing a stator in a rotating electric machine. In this method, each slot has a slot peripheral wall and a slot opening, covered with an insulation coating made of an electrical insulation material. The slot peripheral wall SW has a slot bottom wall, a pair of slot side walls opposing to each other and continuing to end portions of the slot bottom wall. The insulation coating is formed continuously from the slot bottom wall to the pair of slot side walls, and a pair of holding grooves opposing to each other is formed in the insulation coating at the vicinity of the slot opening. The groove walls of the pair of the holding grooves are formed in the insulation coating, and an electrical insulation member to close the slot opening is inserted in the pair of holding grooves and held between the pair of holding grooves.

Abstract: A base plate for magnetic disk drives is provided that includes a hooked protrusion integrated therein between adjacent spindle motor coils. The cross-over wires that span between adjacent coils are secured by the hooked protrusions, thereby optimizing coil height and reducing manufacturing steps. The hook-like protrusions of one embodiment of the present invention are preferably stamped into the base plate.

Abstract: A magnetic core-coil device includes: a printed circuit board having a stack of plate layers, a loop-shaped magnetic core, a primary winding, and an auxiliary winding. The loop-shaped magnetic core has two side portions extending through two rows of through holes of the printed circuit board. The primary winding includes a plurality of primary coil sections formed respectively on the plate layers and each looping around one of the side portions. The auxiliary winding includes a plurality of auxiliary coil sections formed respectively on the plate layers and each looping around the other one of the side portions. A method for making the magnetic core-coil device is also disclosed.

Abstract: An inductor includes: an inductive coil having a coil portion and two extension legs; a magnetic pillar including a pillar portion that is inserted into the coil portion and that has an upper end projecting upwardly from the inductive coil, and a flange portion radially projecting from the upper end of the pillar portion, the flange portion pressing against an upper end of the coil portion; and an embedding body in which the coil portion and the magnetic pillar are embedded, the extension legs being exposed from the embedding body.