Abstract: A system and method is provided for ground testing of a yaw system of a nacelle (3) prior to erection of a wind turbine (1). A portable transformer box (10) is provided which will allow the nacelle preparation team to operate the yaw and hydraulic systems while the nacelle is grounded prior to erection.

Abstract: A transformer station is disclosed comprising a foundation plate and a building with a transformer positioned on top of the foundation plate. The foundation plate is provided with a docking station comprising a first electrical connector. The building with the transformer is provided with a corresponding second electrical connector configured for direct mating with the first electrical connector when the building is placed onto the foundation plate. The transformer station is installed by: providing the foundation plate with a docking station having a first electrical connector; providing the building with a corresponding second electrical connector for connection with the first electrical connector; and placing the building onto the foundation plate with the first and second electrical connectors mating to each other.

Abstract: A power supply circuit enabling provision of good energy efficiency and downsizing is provided. A power supply circuit 1 according to the present invention includes: input terminals 2, 2 connected to a commercial power supply 10; a winding 4 serially connected between the input terminals 2, 2 via input conductors 3; and a plurality of output terminals 6A, 6B connected to opposite ends of respective windings 4A and 4B resulting from dividing the entire winding 4 into a plurality of parts via output conductors, the respective output terminals 6A and 6B being independently connected to respective loads 20A and 20B.

Abstract: Improvements in a power transformer condition monitor are disclosed with this application. The monitor operates with older existing transformers with and without integrated sensors and allows the device to determine the condition of transformers. The sensors monitor one or a multiple of voltage, current, temperature and or power factor. Thermal sensors are magnetically attached to the exterior of the power transformer. Voltage and current sensors are connected to the primary and secondary conductive wires. The monitor can be parasitically powered to operate with limited battery size. The only use of batteries or storage capacitors is when the supply voltage is lost. The monitor uses a localized board can have a large plurality of inputs for sensors. This allows multiple transformers to be locally connected to the monitor and thereby reduce the number of different communication devices and communication addresses over a Mesh, GPRS Cell network link network.

Abstract: An electrical connector between an induction sensor and a cable for transmitting a signal provided by the sensor, including a current transformer with a primary coil and a mechanism for electrically coupling to the sensor, and a secondary coil with a mechanism for electrically coupling to the cable, the primary and secondary coils being attached together by a removable attachment mechanism.

Abstract: A field coil assembly of an electromagnetic clutch for a compressor and a method for manufacturing the same, wherein the field coil assembly includes a coil installed in a core and made by winding a wire W and a connector coupled thereto. The connector is provided with a terminal which is electrically connected to one end of the wire W. A protective coating is formed at a connecting portion between the terminal and the end of the wire W to prevent the connecting portion of the wire W and the terminal from being exposed to the outside. Accordingly, the connecting portion between the terminal and the coil is not exposed to moisture or air, thereby preventing electric short circuit from occurring by galvanic corrosion between the terminal and the coil.

Abstract: An ignition coil includes a coil body, a primary resin molded body, and a secondary resin molded body. The coil body has a primary coil and a secondary coil. The primary resin molded body has the coil body therein in a fixed relation, and the primary resin molded body has a plurality of exposed side portions that hold the coil body therebetween. The secondary resin molded body is molded to have the coil body and the primary resin molded body embedded therein. The secondary resin molded body is configured to allow the plurality of exposed side portions of the primary resin molded body to be exposed to an exterior of the secondary resin molded body.

Abstract: The present invention relates to an electric power connection part of an electromagnetic cluth field coil assembly coupled with a vehicle compressor. Since the electric power connection part has the discharge device and/or the magnetic field elimination device and the terminal which are integrally formed by injection molding in the housing assembly of a electromagnetic cluth field coil assembly, it is possible to rapidly and facilely perform the assembling process, increase the productivity and also reduce fabricating costs.

Abstract: A system and method is provided for ground testing of a yaw system of a nacelle (3) prior to erection of a wind turbine (1). A portable transformer box (10) is provided which will allow the nacelle preparation team to operate the yaw and hydraulic systems while the nacelle is grounded prior to erection.

Abstract: A bushing for electrical current and/or voltage through a grounded plane. A substantially rotationally symmetrical insulating body surrounds a central electrical conductor. The bushing includes a sealing member for gas/liquid sealing between the conductor and the insulator body. The bushing includes a compressible sealing element, which forms a gas/liquid seal, integrated with the insulating body, between the conductor and the insulating body. A method of manufacturing a bushing.

Abstract: Disclosed herein are various embodiments of coil transducers and galvanic isolators configured to provide high voltage isolation and high voltage breakdown performance characteristics in small packages. A coil transducer is provided across which data or power signals may be transmitted and received by primary and secondary coils disposed on opposing sides thereof without high voltage breakdowns occurring therebetween. At least portions of the coil transducer are formed of an electrically insulating, non-metallic, non-semiconductor, low dielectric loss material. The coil transducer may be formed in a small package using, by way of example, printed circuit board, CMOS-compatible and other fabrication and packaging processes.

Abstract: A multilayer inductor is disclosed. The multilayer inductor includes a bottom magnetic layer having an external conductive pattern formed on a bottom surface thereof for connection to a substrate such as a printed circuit board. The bottom external conductive pattern includes signal/power contacts and first and second inductor electrodes. A top magnetic layer includes a top external conductive pattern having signal/power contacts and inductor electrode contacts. An inductor conductive pattern formed on the top surfaces of intermediate magnetic layers disposed between the top and bottom magnetic layers are electrically coupled to each other by means of through holes to form a spiral inductor element. The spiral inductor element is coupled to the first inductor electrode by means of a through hole formed in the bottom magnetic layer and to the second inductor electrode by means of power conductive traces formed on side surfaces of the multilayer inductor.

Abstract: A connector includes: an insulative housing having a mating port formed between a pair of front wall and rear wall, and a pair of side walls thereof, the mating port defining a first direction for mating/un-mating a corresponding plug, and a second direction extending transversely and perpendicular to said first direction, and a third direction extending vertically and perpendicular to both said first and second directions; a shutter mechanism pivotally mounted to the insulative housing and having a pair of axles extending from two sides thereof in the second direction; wherein the side wall defines a first slot at an inner side thereof and a second slot at an outer side thereof, the second slot extending in the first direction, the first slot extending in a direction different from the second slot and overlapping with the second slot in the second direction to form an opening to receive the axles.

Abstract: A dual sided connector block for a solenoid is provided which may be used in multiple designs. The dual sided connector block includes a base, a first terminal insertion slot on a first side of the base, a second terminal insertion slot on the second side of the base, a tie-off post, and a magnet wire. The magnet wire is operatively configured as a solenoid coil and is routed inside of the base and wound around the tie off post. The magnet wire is accessible to a connector blade inserted through either the first terminal insertion slot or the second terminal insertion slot.

Abstract: An electrical connector includes an insulating body, which has plural front and rear rows of accommodating troughs for receiving electrical conductive terminals, and two protective blocks protruded upwardly. The accommodating portion has a first accommodating portion, a second accommodating portion extending laterally from the first accommodating portion, and a third accommodating portion extending rearwards from the first accommodating portion. A rear row of the second accommodating portions are located behind the adjacent front row of third accommodating portions. The electrical conductive terminal has a base, a material-belt connecting portion extending from one side of the base, an elastic arm extending from the elastic arm. The elastic arm is adjacent to and exceeds the material-belt connecting portion. The elastic arms of the rear row of the electrical conductive terminals are located between the two adjacent elastic arms of the front row of the electrical conductive terminals.

Abstract: The present invention relates to a field coil assembly of an electromagnetic clutch for a compressor. A field coil assembly according to the present invention includes a field coil member 20 having a coil wire 22 extending outward; a power connecting member 30 having a sleeve 35 with a terminal 40 protruding out, the terminal electrically connecting the coil wire 22 to an external power source; a flange 28 coupled to one side of the field coil member 20 with the coil wire 22 drawn therefrom, the flange 28 having a catching portion 29 coupled with the sleeve 35, the flange 28 having electric conductivity; and a ground terminal 50 provided in the sleeve 35 and electrically connected to the terminal 40, the ground terminal 50 having at least a portion contacted with the catching portion 29.

Abstract: The subject matter of the invention is an electric coil such as the coil of a choke or of a transformer, said coil comprising at least one connecting member for connection to a printed circuit board, said connecting member (10) being configured to be a contacting dome, said contacting dome (10) comprising at least one cable socket (13), said printed circuit board (20) comprising a bridge (21) that is electrically connected to said printed circuit board (20), said bridge (21) being adapted for electrically conductive connection with the cable socket (13).

Abstract: An electric terminal member includes a connector portion (4), a wire connecting portion (6) spaced apart from the connector portion and lying parallel to the connector portion, and a bridge portion (8) extending between one end of the connector portion and one end of the wire connecting portion in a direction transverse to any one of the connector and wire connecting portions and for connecting the connector portion with the wire connecting portion. The wire connecting portion has a retaining hole (12). The wire connecting portion also has a flux applying surface (18) and a wire holding surface (16) opposite to each other, the flux applying surface facing towards the connector portion whereas the wire holding surface faces in a direction away from the connector portion.

Abstract: An underwater connector (10) comprising a magnetic coupler for passing communications signals and/or power from one part (12) to another part (13) using magnetic coupling and without requiring direct electrically conductive contact between the parts (12, 13).

Abstract: A connector and a power transformer structure comprising the same are provided. The power transformer structure comprises a connector and an integrated transformer. The connector comprises a plurality of connection units, and the integrated transformer comprises a plurality of transformation units. The transformation units are sequentially stacked and electronically connected to the corresponding connection units in contact connection to reduce the current conduction consumption and contact resistance.

Abstract: The invention relates to an actuating device, particularly an actuating magnet, for actuating valves. In order to improve the sealing action of an actuating magnet, the invention provides that a contacting plug insert (48) has a seating surface (54) against which an annular sealing part (52) rests and which extends in the form of a groove inside the plug insert (48). The groove depth is selected so that, when in an unpressed state, approximately half of the sealing part (52) is accommodated inside the groove (56). When the groove (56) is fitted with the sealing part (52), it is completely filled whereby resulting in a projection that sealingly closes the gap (58) arising between a plug plate (40) and an outer peripheral surface (50) of the housing (18).

Abstract: A transformer includes a circuit board, a conductive winding structure and a magnetic core assembly. The circuit board has a trace pattern of a primary winding coil and a first through-hole. The first segment has a first pin and a first hollow portion. The second segment has a first end coupled with the first segment, and a second end formed as a second pin and a second hollow portion. The second segment is folded toward the first segment with respect to a folding line such that the first hollow portion and the second hollow portion are aligned with each other to define a second through-hole. The magnetic core assembly is partially embedded into the first through-hole of the circuit board and the second through-hole of the conductive winding structure.

Abstract: An electric device capable of handling high speed data communication and which could be used with, for example, a connector application such as an RJ45 type connector. The electric device is formed by inserting at least one wire through a first hole in a core, wrapping the wire around a side of the core, and inserting the wire through a second hole in the core a desired number of times. A common mode choke may be combined with the electric device. To form such a choke, two of the wires from the electric device may be wrapped around a second core in the same fashion a desired number of times.

Abstract: An ignition coil, which includes a primary coil and a secondary coil, has an electrical insulating member. The electrical insulating member includes an insulating material being a base material. The electrical insulating member further includes a reactive agent being an additive added to the insulating material for causing dehydration-decomposition, so as to enhance durability when being applied with high voltage. Alternatively, a reactive agent is coated on a surface of the electrical insulating body for causing dehydration-decomposition, so as to enhance durability when being applied with high voltage.

Abstract: An ignition coil includes primary and secondary coils accommodated in a coil case extending to define a cylindrical mount portion on a high voltage side. The mount portion includes a high voltage terminal electrically connected with the secondary coil. A coil spring electrically connects the high voltage terminal with a sparkplug. An electrically insulative plug cap is attached to the mount portion. The coil spring has a low voltage end electrically connected with the secondary coil via the high voltage terminal. The coil spring has a high voltage end in contact with a terminal of the sparkplug. The coil spring has an intermediate portion between the low voltage end and the high voltage end. The plug cap has a spring support portion, which is partially defining the fitting hole and restricting the intermediate portion of the coil spring from being radially deformed.

Abstract: An adjustable-inductance (AI) filter, a tape distribution substrate including the filter, and a display panel assembly including the tape distribution substrate are provided. The adjustable-inductance (AI) filter includes a filter distribution line including first and second end portions each having a first line width, at least one repair pattern having a second line width and disposed between the first and second end portions, and at least one unit filter bank connected in parallel to the at least one repair pattern, respectively.

Abstract: An electrical reactor assembly and method of assembly is disclosed. The reactor is formed from a combination of a magnetic T-core and a pair of magnetic L-cores. A plurality of comb-like separators is placed over a vertical portion of the T-core. A wire, with a rectangular cross-section, is wound about the vertical portion of the T-core thereby forming a coil. The comb-like separators electrically isolate the wire from adjacent windings and the T-core. The L-cores are attached to the T-core such that they flank two sides of the coil. A plurality of taps is formed on a side of the coil that is not flanked by one of the L-cores. The taps are formed by extending individual windings further from the T-core than other common windings. Preferably, a hole is formed through the rectangular wire at the taps to provide a secure electrical connection to the wire.

Abstract: To provide a structure capable of securing satisfactory induction coupling efficiency and high reliability in manufacturing an induction coupling apparatus used in power line carrier communication, the induction coupling apparatus having a magnetic core formed from a first core element part and a second core element part so that a gap would be formed between the core element parts, includes: a core parallel moving mechanism for carrying out relative and parallel movement of the first core element part and the second core element part in a direction that the length of the gap varies; and a predetermined gap length regulating member for limiting parallel movement in a direction that the first core element part and the second core element part approach each other to regulate the gap length to the predetermined gap length in the case that the core parallel moving mechanism is used for the parallel movement.

Abstract: A luminaire has a ballasting circuit assembly for a gas discharge lamp, with an input power connector assembly suitable for receiving and connecting with a mating multi-conductor connector assembly. A ballasting circuit in the ballasting circuit assembly is suitable for powering a gas discharge lamp. Output leads suitable for connecting to a gas-discharge lamp socket with the wiring therefore are contained within the luminaire.

Abstract: A voltage-controlled rectifier is disclosed to include a circuit board, which has a circuit electrically connected to the positive and negative terminals of the car battery of a car, a capacitor set formed of a plurality of capacitors connected in parallel to the circuit on the circuit board, and a rectifying unit, which has a connecting member and a winding eccentrically wound round the connecting member and electrically connected in series to the capacitor set.

Abstract: An ignition coil is disclosed. The ignition coil includes an insulative material, a body, and a head coupled to the body. A portion of the insulative material is included in the body, and a portion of the insulative material is included in the head. The head includes a casing, a flange for coupling to an engine case, and a connector adapted to be connected to an external device. The head also includes a conducting terminal with a connector pin, an exposed contact, and a connecting part. The connector pin is coupled to the connector, the exposed contact is coupled to the casing or the flange, and the connecting part couples the exposed contact and the connector pin. A portion of the connecting part is embedded in the insulative material, and wherein a remaining portion is embedded in the casing. A method of manufacturing the ignition coil is also disclosed.

Abstract: The present invention relates to an assembling structure of field coil, which has a simple mounting structure for a diode and a resistor to cut an off-noise of an electromagnetic clutch and to prevent damage of peripheral parts due to surge voltage generation when power source applied to an electronic coil body is cut off, thereby improving a mounting efficiency, reducing a manufacturing cost by reduction of the number of parts, and realizing an automatic production. The assembling structure of field coil includes an electronic coil body (101), a core ring (110) and a sleeve (120) having a first and second terminals (131) (132), and a case that has a receiving part (135) and a first and second connection parts (136) (137).

Abstract: A switchgear, especially for actuating valves, includes a housing (18) and a coil body (10) disposed in the housing. A switch element is guided in the coil body. The coil body is provided with a winding (14) of a conductor (16) that is connected to a plug connector (22) via contact elements (20). At least some sections of the housing (18) and of the plug connector (22) are enclosed by a plastic compound (24). Sealing devices (40) seal off the interior (42) of the switchgear from the surroundings (44). At least one of the sealing devices (40) is configured as a sealing web (48) of a meltable material. The sealing web (48) is disposed on the bottom face (50) of a plug plate (26) of the plug connector (22) which faces the housing (18).

Abstract: The present invention relates to a field coil assembly of an electromagnetic clutch for a compressor, in which a coil wire of an electromagnetic coil body exposed to a protrusion of a bobbin is electrically connected with a compressing portion of a coil wire formed at one side end portion of terminals mounted inside a sleeve, and the terminals and the electromagnetic coil body are molded with the resin, thereby preventing permeation of foreign matters from the outside, preventing disconnection of the coil wires due to vibration, and simplifying a manufacturing process.

Abstract: A solenoid including a substantially cylindrical hollow bobbin made of an insulating material is provided, which is mountable on a housing body and is provided with at least two relay connectors anchored in an end area of the bobbin and projecting axially therefrom, and the solenoid is also coupled to a contact element. The solenoid and the contact element are two separate components which are connectable to each other by a connecting part of the contact element attachable to the housing body, by a suitable securing method, e.g., by soldering or welding.

Abstract: An axially potted progressive wound remote mount ignition coil (axially potted ignition coil) includes a coil case, at least one coil assembly, and a quantity of potting material. Each coil assembly is progressively wound. The coil case includes a coil cavity for each coil assembly, a primary connector, and two secondary connectors for each coil cavity. Each primary coil is connected to the primary connector and an end of each secondary coil is connected to a single secondary connector. A quantity of potting material is poured over the open end of each coil cavity. A second embodiment of the axial potted ignition coil includes a modular coil case, at least one coil assembly, and a quantity of potting material. The modular coil case includes at least one coil tube, a rear end cap and a forward end cap. Each coil assembly is inserted into a respective coil tube.

Abstract: Providing a high-voltage-side terminal with means for preventing a core inserted into a central hole of a bobbin from getting out of position securely fixes the core to the predetermined position, at the time a transformer which is a part of an ignitor is assembled, during the work proceeds from the inserting step of the core to the next step. Thus, at the time the ignitor-integral type bulb socket is assembled, the core hardly moves out of the predetermined position and there is a less possibility that the core gets out of position. Accordingly, this does not require so high machining accuracy of both members and reduces the cost for machining the product as well as for inspecting the dimension control or the like.

Abstract: A coil assembly includes a spool having a wire wound therearound to establish a coil. A spool terminal extends from the spool and the end of the wire is wound around the spool terminal. A connector housing is coupled to the spool and a connector terminal extends therefrom. A portion of the connector terminal is adjacent to a portion of the spool terminal. Thus, the connector terminal can be relatively easily resistance welded or soldered to the spool terminal.

Abstract: An ignition coil includes a connecting device for contacting a spark plug of an internal combustion engine, the connecting device being designed to have a sleeve made of insulating material. The sleeve is able to be connected at a first end section to a high voltage side of the ignition coil, and at a second end section has an accommodation for the spark plug. Furthermore, in the sleeve at least one conductive contact part, touching the spark plug, is situated for the electrical connection of the ignition coil to the spark plug. At the high voltage side of the ignition coil, between it and the spark plug, a plurality of electrically conductive modular components are able to be positioned, which in the installed state are connected in a detachable, electrically conducting manner.

Abstract: A coil device includes terminal electrodes each including a bottom-surface electrode provided on a bottom surface of a flange, side-surface electrodes provided on side surfaces of the flange, and an end-surface electrode provided on an end surface of the flange at the lower part of the end surface. The end-surface electrode is arranged on the end surface of the flange so that the upper edge of the end-surface electrode is disposed at a first level that is substantially the same as that of the upper edges of the side-surface electrodes in the vicinity of boundaries between the end surface and each side surface of the flange and is disposed at a second level lower than the first level at an approximate central portion of the end surface of the flange.

Abstract: An electric solenoid with adaptable terminals and posts to connect to a variety of different electric connectors, and with a multiple-eared mounting plate permitting mounting in a variety of configurations. The solenoid posts combine internally-threaded female post receptors integrally molded into the solenoid casing, with removable post studs, one end of which is threaded to screw into the respective female post receptor. The other end of the removable post studs are also threaded, and can be formed in a variety of different sizes to accommodate a variety of connectors as needed for a particular application. The energizing terminal (and ground terminal, if present) can accommodate a variety of connector types, including eyelet leads, push-on connectors, and spade connectors.

Abstract: A primary winding 12 connected to a high-voltage, a large-current power supply 1, a secondary winding 14 connected to an electromagnetic forming coil 2, and a magnetic core 16 for guiding the magnetic flux produced by the primary winding. The magnetic core 16 is composed of a primary core 16a on which the primary winding is wound and a secondary core 16b on which the secondary winding is wound. The primary core and the secondary core are magnetically connected in contact or in close proximity. The primary core and the secondary core are separated each other when the connector is disconnected. Thus, current pulses at a high voltage (for instance, 10 kV) with a large current (for example, 100 kA or more) and a narrow pulse width (e.g., 30 &mgr;sec or less) can be efficiently transmitted, and the connector easily attached and removed.

Abstract: A porcelain bushing for transformers withstanding impulse voltages rated at 45 kV and 1.2/50 &mgr;s without external flashover, having a creepage to arcing distance ratio of 1.05 to 1.24. The bushing includes a body constituted by a flange fitted with a gasket seat groove, a neck having a curvature radius ranging from 5 to 7 mm, and a mouth equipped with a two-level stepped gasket seat and a semicircular groove. A threaded shank for the attachment of the porcelain bushing to the mounting surface and a groove rail extending along the shank's thread is also provided. In a preferred embodiment, the body is coated with glassy enamel in order to protect the porcelain material against contamination by external agents as well as against the adoption of water.

Abstract: A conductive member is disposed between a secondary spool and a high tension terminal to shield the wire connecting the secondary coil and the high tension terminal. The conductive member has a wide surface facing the low tension components to moderate the electric field strength around low tension components, thereby preventing treeings from growing in the insulating filler of the ignition coil.

Abstract: An electrical assembly that prevents contaminants from migrating to the coil windings within an encapsulant forming the main housing through the use of a sealing assembly located within an over-molded, thermoplastic encapsulant. Before over-molding, an elastomeric seal is installed on each lead wire to be sealed, and this wire/seal subassembly is then inserted into a seal housing made from the same basic thermoplastic as the encapsulant forming the housing. The seal housing has one or more continuous ribs, with sharp edges, that circumvent the outer surface of the seal housing. During over-molding to form the main housing, the molten encapsulant surrounds the seal housing and melts the tips of the ribs. Upon cooling, the (no thermoplastic solidifies and the encapsulant bonds to the seal housing along each of its ribs.

Abstract: An ignition apparatus includes a high voltage (HV) terminal formed of stamped sheet metal configured to be disposed in a secondary winding spool, and to which a high voltage end of the secondary winding is attached and soldered. The ignition apparatus further includes an electrically conductive cup configured to surround the high voltage terminal when the secondary winding spool is inserted in the case. The high voltage terminal has one end that comes into engagement with an inner annular surface of the cup. The cup includes an annular sidewall that extends axially up to a winding flange where a HV end of the secondary winding exits a winding bay thereby surrunding the exiting HV secondary winding wire. The cup provides for a reduced electric field concentration.

Abstract: To provide a coil bobbin for a transformer in which no through hole is formed in both sides of an upper flange to thereby prevent upsizing, and no long arm apt to splinter is formed on a terminal board, and the terminal board can be readily mounted to a flange. In the coil bobbin in which an end of an upper flange (3) formed on an upper end of a drum (2) is formed with a terminal board mounting portion (5), and in which a separately formed terminal board (8) is mountable on the terminal board mounting portion (5), an inside of the terminal board mounting portion (5) is formed with a rib (7), whose upper portion is formed with a plurality of plate-like walls, and an inner end of the terminal board (8) is formed with a plurality of through holes (17) in which said walls are inserted.

Abstract: A coil assembly includes a spool having a wire wound therearound to establish a coil. A spool terminal extends from the spool and the end of the wire is wound around the spool terminal. A connector housing is coupled to the spool and a connector terminal extends therefrom. A portion of the connector terminal is adjacent to a portion of the spool terminal. Thus, the connector terminal can be relatively easily resistance welded or soldered to the spool terminal.

Abstract: An ignition coil assembly of the type which is directly mounted onto an associated internal combustion engine spark plug. The coil assembly includes a spark plug boot section made of a highly elastic material with an inside cylindrical passageway. The inside passageway features ribs which engage a high voltage connection coil spring positioned in the passageway to make an electrical connection between the coil and spark plug high voltage terminals. The spring has a generally constant outside diameter outer section except its end segments have a reduced diameter where they contact the high voltage terminals. The passageway ribs retain the spring in position prior to its installation and after its removal from the associated spark plug.

Abstract: An advanced microelectronic coil device incorporating a toroidal core and a plurality of sets of windings, wherein the windings are separated by one or more layers of insulating material. In one embodiment, the insulating material is vacuum-deposited over the top of a first set of windings before the next set of windings is wound onto the core. In this fashion, the insulating material insulates the entire first winding from the second without the need for individual insulation on each of the windings, or the use of margin tape. The use of the vacuum-deposited insulating layer(s) provides a high degree of dielectric strength, yet consumes a minimum space since the insulation on each winding is minimized. The toroidal core is also optionally provided with a controlled thickness gap for controlling saturation of the core.