Abstract: The present invention provides an improved transformer (20), which broadly includes: a substrate (21) having first and second surfaces (22, 23); a first board (24) mounted on the substrate first surface; a second board (25) mounted on the substrate second surface; the boards being identical to one another and being mounted on the respective proximate substrate surfaces as mirror images of one another; each of the boards having a plurality of dielectric layers with electrically-conductive sheet windings (35, 36, 37, 38) embedded therein; and an assembled core (26, 28) operatively arranged to provide a path for magnetic flux attributable to a current in some of the windings. Third and fourth boards (71, 72) may be piggy-backed onto the first and second boards, respectively, to selectively vary the properties of the transformer.

Abstract: A signal isolating transformer may be arranged such that a first coil of the signal isolating transformer is located in a medium voltage compartment and a second coil of the signal isolating transformer is located external to the medium voltage compartment. The transformer spans an opening defined by a grounded wall to isolate faults in the medium voltage compartment.

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

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

Abstract: A coil component having an easily discernible orientation, and a method of producing such a coil component that facilitates the injection of resin. A coil component includes a core with a winding portion, first and second flanges disposed on either end of the winding portion, and a winding accommodating region defined by the winding portion and the first and second flanges, terminal electrodes disposed on the second flange and a winding wound about the winding portion and connected to the terminal electrodes. An insulating resin is formed over the winding at the winding accommodating region. A marker made from a material the same as the insulating resin is provided at outer peripheral surface of the flanges.

Abstract: A coil device includes a first coil pattern, a second coil pattern, an insulating layer, a magnetic covering element and a number of conductive pillars. The second coil pattern is disposed above the first coil pattern, and is spaced apart from the first coil pattern. The insulating layer covers the first coil pattern and the second coil pattern and defines an opening surrounded by the first coil pattern and the second coil pattern. The magnetic covering element covers the insulating layer and extends into the opening. The conductive pillars are disposed within the magnetic covering element and are exposed from a bottom side of the magnetic covering element. A portion of the conductive pillars are electrically connected to the first coil pattern, and another portion of the conductive pillars are connected to the second coil pattern. The coil device can be easily manufactured.

Abstract: The present invention provides a novel direct current thyristor valve saturated reactor includes: case, winding in the case, iron cores, cooling fins, pipes and press fit mechanism. The iron cores are coupled with winding. The invention having the following advantages: simple, modular design, low connection capacity of the wingding, fixed dimension, winding and irons well-cooled, small noise and vibration. The saturated reactor is particularly suitable used as the positive saturated reactor for high voltage current thyristor valve.

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: Disclosed is an electronic component, especially a coil with a coil core, in which the turns of the coil winding are spaced apart from each other at least at one point in the longitudinal direction of the coil. A plastic retaining element which overlaps both the coil core and at least the two adjacent turns of the coil winding in a longitudinal direction is sprayed on in the area of said point, whereby a connection between the coil core and the coil winding is created at the same time. The retaining element can be sprayed around a closed circumference of the coil while covering only a portion of the coil in the longitudinal direction thereof. Preferably, the retaining element is placed approximately in the center relative to the longitudinal extension of the coil.

Abstract: The inductor for a semiconductor device includes at least one dielectric pattern selectively formed on a top of the interlayer dielectric, at least one first metal wire formed on a top of the interlayer dielectric, at least one second metal wire formed on a top of the dielectric pattern, and an upper protective film formed on the top of the interlayer dielectric to completely cover the first and second metal wires, wherein the first and second metal wires are alternately arranged at different vertical locations and are formed in a spiral configuration.

Abstract: A method of producing a surface-mount inductor by encapsulating a coil with an encapsulation material containing a resin and a filler using a mold die assembly is provided. In the method, a tablet and a coil are used. The tablet is prepared by preforming the encapsulation material into a shape having a flat plate-shaped portion and a pillar-shaped convex portion on a peripheral thereof. The coil is a wound conductive wire having a cross-section of rectangular-shape. The coil is placed on the tablet to allow both ends of the coil to extend along an outer side surface of the pillar-shaped convex portion of the tablet. The coil and the encapsulation material are integrated together while clamping the both ends of the coil between an inner wall surface of the mold die assembly and the outer side surface of the pillar-shaped convex portion of the tablet, to form a molded body.

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: 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: A low profile magnetic component with planar coil portion, polymer-based supporting structure and methods of fabrication.

Abstract: A method of manufacturing a 3-D spiral stacked inductor is provided having a substrate with a plurality of turns in a plurality of levels wherein the number of levels increases from an inner turn to the outer turn of the inductor. First and second connecting portions are respectively connected to an inner turn and an outermost turn, and a dielectric material contains the first and second connecting portions and the plurality of turns over the substrate.

Abstract: An improved choke assembly for a power electronics device is provided. More specifically, a choke assembly with improved protection from environmental conditions such as dirt and water is provided. An improved choke assembly may include a double layer of protection around an inductor coil of a choke that seals the inductor coil from the outside environment. Another embodiment may include a choke with a projection that seals the cabinet from the cooling channel while allowing the choke leads to pass into the cabinet.

Abstract: The inductance component has a base material, a coil formed in the base material and an electrode electrically connected to the coil. In addition, an impact-absorption layer is disposed between the electrode and the base material. Forming impact-absorption layer between the base material and the electrode allows the base material to have flexibility even if an impact is given on the base material, providing the component with high impact-resistance.

Abstract: The invention relates to a coil for producing a magnetic field having at least one winding (12), which is manufactured from a superconductor, is cast into a plastic and whose winding end (19) which is arranged at the circumference (13) of the winding (12) is used for making contact with an electrical conductor (15). In order to provide coils with windings (12) consisting of superconductors which make robust contact-making possible given simple production, an electrically conductive connection piece (30) with a base region (31), which is connected to the winding end (19), and a top region (32) for connecting the conductor (15) is provided for contact-making purposes, the base region (31) of said connection piece (30) being covered partially in the radial direction by a reinforcing insert (14), which is cast into the plastic (20) and at least partially surrounds the winding (12).

Abstract: Disclosed is an electronic component, especially a coil with a coil core, in which the turns of the coil winding are spaced apart from each other at least at one point in the longitudinal direction of the coil. A plastic retaining element which overlaps both the coil core and at least the two adjacent turns of the coil winding in a longitudinal direction is sprayed on in the area of said point, whereby a connection between the coil core and the coil winding is created at the same time. The retaining element can be sprayed around a closed circumference of the coil while covering only a portion of the coil in the longitudinal direction thereof. Preferably, the retaining element is placed approximately in the center relative to the longitudinal extension of the coil.

Abstract: A method of fabricating an inductor includes selecting a substrate, depositing a layer of magnetic material on the substrate, depositing an insulating layer on the magnetic material layer, forming a inductor pattern from gold on the insulating layer, depositing a second insulating layer on the inductor pattern, and depositing a second magnetic material layer on the second insulating layer.

Abstract: The invention relates to a winding for a transformer or a coil. Said winding is made of a winding material comprising a strip-type electric conductor which is connected in a detachable manner to at least one wide side having at least one layer of insulating material. The winding material is wound about a winding axis in order to prevent axial offset in order to form the threads. The invention further relates to a method for the production of said type of winding.

Abstract: A laminated coil component includes a spiral coil including laminated ceramic films and coil conductors. Pad portions provided at ends of the coil conductors are connected to one another using via-hole conductors to provide an interlayer connection among the pad portions. Thus, a spiral coil is provided. The pad portions are thinner than the coil conductors, and accordingly, a concentration of stress on portions at which the pad portions and the via-hole conductors overlap one another is reduced.

Abstract: A method for producing an insulated wire having a cross section of a desired shape, in which a conductor having a cross section of a desired shape is coated with an insulating film, which method comprises: supplying a raw conductor while passing through a rolling unit composed of at least one pair of rolling rolls that are capable of freely rotating without a drive mechanism and that have a desired shape, thereby forming a conductor having a cross section of a desired shape; and coating the conductor with an insulating film.

Abstract: An ignition coil for an internal combustion engine includes: an iron core; a primary coil wound around the iron core via a primary bobbin; a secondary coil provided to externally surround the primary coil; a ground terminal fitting placed with a part thereof being held between the primary bobbin and the iron core; and a resin-molded portion provided to cover the primary coil and the secondary coil, a ground side terminal portion of the primary coil being connected to the ground terminal fitting, wherein at least one protrusion is formed in the part of the ground terminal fitting held between the primary bobbin and the iron core, and the protrusion has a pointed tip that is brought into contact with the iron core.

Abstract: An induction heating coil having little high-frequency loss and producing little hast is easily manufactured by covering a conductor with a first insulating material to form a wire, then bundling and twisting such wires to form a stranded wire, covering the outer surface of the stranded wire with a second insulating material to form a coil wire, winding the coil wire a certain number of turns into a coil portion having a certain shape. The end portion of the coil portion and a connecting portion are heated with Joule heat while applying pressure to the end portion at the same time, so that the first and second insulating materials are fused and pressure-bonded to the conductor. Thus a terminal portion for the external connection of the coil portion is fixed while keeping the electrical connection with the conductor. Accordingly, an induction heating coil of low cost and stable quality can be easily manufactured.

Abstract: A winding for a transformer or a coil having a ribbon electrical conductor and an insulating material layer composed of ribbon insulation material wound jointly to form turns around a winding core. The individual turns of the winding have a predetermined winding angle with respect to a winding axis of the winding core and are disposed such that they partially overlap one another. An insulating layer is inserted between two radially adjacent layers of the turns. Furthermore, a thickness of the insulating layer is locally matched to the voltage difference determined there. In addition, the thickness of the insulating layer is locally matched, the thickness being interchanged in sequence of the method A+B determined there, to the voltage difference between the two relevant radially adjacent layers at the relevant axial point.

Abstract: A jig (10) is used to form a coil (50) for an electrical machine. A plurality of conductive wires (56), each covered in a heat-curable electrically insulated material, are wound around a bobbin (12). Each succeeding winding in contra-wound relative to the previous winding, with the first turn (16) of each succeeding winding overlaying the last turn (5) of the previous winding. Undeformable electrically insulated inserts (54) are inserted into the windings before heating and compressing the coil (50) in the jig (10).

Abstract: The winding of matrix transformers having multiple turn primary windings is made much easier, and the resulting transformer is much more consistent, if a “cellular” insert having a plurality of through holes is placed through each trough hole of the matrix transformer. Preferably, there is one hole in the cellular insert for each wire, though two or more wires can be placed in each hole. In one embodiment, insulating cellular inserts are placed through the entire length of the cellular transformer to guide and locate the primary windings. In another embodiment, each element of the cellular transformer has cellular inserts, and the elements are coupled together. In another embodiment, the cellular insert is a conductor and is part of the secondary circuit.

Abstract: An inductive coil assembly having multiple coils arranged at distinct orientations to provide efficient inductive coupling of power or communications or both to a device when the device is arranged at different orientations with respect to the inductive primary coil. In one embodiment, the inductive coil assembly includes three coils, each oriented along one of the x, y and z axes of a standard Cartesian three-dimensional coordinate system. The three separate coils provide effective transfer of power and communication when the device is at essentially any orientation with respect to the primary coil. In an alternative embodiment, the multi-axis inductive coil assembly of the present invention can function as a primary to inductively transmit power or communication or both over a plurality of magnetic fields at distinct orientations.

Abstract: The present invention relates to a power transformer/inductor comprising at least one winding. The windings are designed by means of a high-voltage cable, comprising an electric conductor, and around the conductor there is arranged a first semiconducting layer, around the first semiconducting layer there is arranged an insulating layer and around the insulating layer there is arranged a second semiconducting layer. The second semiconducting layer is earthed at or in the vicinity of both ends (261, 262; 281, 282) of each winding and furthermore one point between both ends (261, 262; 281, 282) is directly earthed.

Abstract: An inductive device (10) comprises a magnetic core (16) including a portion of a plurality of wires (18), an electric winding (20) extending around said magnetic core, with one or more of the plurality of wires (18) at least partially encircling the electric winding (20) and having first and second end portions (26) arranged so as to form a gap (24) therebetween, and a flux coupling structure (28) disposed in a vicinity of the gap (24) so as to enhance coupling of magnetic flux between the first and second end portions (26).

Abstract: In one embodiment, a method for fabricating electromagnetic meta-materials includes applying first and second array of electromagnetically reactive patterns to first and second non-conducting surfaces, wherein the first array includes at least one of a split ring resonator pattern, a square split ring resonator pattern, and a swiss roll pattern, and the second array includes a thin parallel wire pattern. The first and second non-conducting surfaces are joined together such that the first and second non-conducting surfaces bearing the first and second arrays of electromagnetically reactive patterns are commonly oriented. Alternately, a method may further include slicing between elements of the first and second arrays of electromagnetically reactive patterns in a plane perpendicular to the first and second surfaces to form a plurality of slices, rotating at least one of the slices, and applying a third array of electromagnetically reactive patterns to a third non-conducting surface.

Abstract: An ignition coil apparatus for an internal combustion engine does not generate a discharge between a high-voltage terminal and an iron core even if a high-voltage cable falls off from a high-voltage side connector, and the overall height thereof can be reduced. An ignition coil has an iron core disposed in a casing to form a closed magnetic circuit, and primary and secondary coils installed on a part of the iron core. A power switch controls electric power supplied to the primary coil. A low-voltage side connector has a terminal electrically connected with the power switch. A high-voltage side connector has a high-voltage terminal electrically connected with the secondary coil. The casing includes a casing main body accommodating the part of the iron core, the primary and secondary coils and the power switch, and a cover integral with the main body for covering a part of the iron core located outside thereof.

Abstract: An externally adjustable RF impedance matching mechanism comprises an upper lid and a base containing a circuit element board therebetween. One or more than one precise adjustment device for adjusting impedance value are provided under the upper lid. Impedance adjustment is carried out by manually turning setting screws associated with the aid of spring force. Heat conductive material is coated between the circuit board and the base so that the device is able to operated at a high power. The expensive material such as ceramic is used in forming the coil board only so that material and the production cost are low.

Abstract: A field coil for an electromagnetic rotor comprising multiple windings, each substantially entirely coated with a powder resin having a dielectric strength of at least in the range of 1000-1500 v/mil. A method of manufacturing a field coil for an electromagnetic rotor includes the steps of a) providing a field coil comprising multiple layers of copper bars; b) coating the multiple layers of the field coil with a powder resin having a dielectric strength of at least about 1000-1500 v/mil.; and c) curing the powder resin.

Abstract: A method of manufacturing an electromagnetic clutch coil assembly provided in a compressor of an air conditioner for an automobile is achieved by forming a coil winding by winding a coil coated with an adhesive, heating the coil winding in a state of being pressed in a direction in which the coil winding is stacked, hardening the coil winding by cooling the coil winding in the state of being pressed in a direction in which the coil winding is stacked, and assembling the coil winding, a bobbin, and a cover in a field core assembly, wherein the adhesive between two neighboring coil layers in a direction in which the coil winding is stacked moves to a nearby empty space. Thus, during the operation of the compressor, the lead wires connected to both ends of the coil winding can be prevented from being damaged or short-circuited due to the vibrations and high temperature.

Abstract: A transformer with good insulation is disclosed. The transformer includes a bobbin, an insulating shell and a core structure. The bobbin is wound with a secondary winding. The insulating shell encloses the bobbin and the insulating shell is wound with a primary winding. Further, the core structure is magnetically coupled to the primary winding and the secondary winding.

Abstract: An electromagnetic coupling apparatus includes a ring case, a coil and a connector. The ring case has an annular groove. The coil is an electrical wire and is disposed in the annular groove of the ring case. An opening is formed through the ring case in its closed end surface. The connector is disposed on the closed end surface of the ring case and covers the opening. Each of a first end and a second end of the coil are connected to one of a pair of lead wires, respectively, of an electric circuit via one of a pair of contacts, respectively in the connector. The connector has a housing supporting the first and the second ends of the coil and the contacts and a cap closing an end opening of the housing. The coil is covered substantially by an annular resin case, and the housing is formed integrally with the annular resin case.

Abstract: An internal heating method for drying, gelling and final curing of epoxy resin insulation systems used for encapsulating dry type cast distribution transformer coils is disclosed. The internal method uses a Direct-Current (DC) power source to control and supply DC current to resistively heat the transformer coil encapsulated with a liquid resin under vacuum in a mold. DC current is applied to a given coil based on its conductor cross-sectional area and its epoxy resin quantity to achieve a specified temperature for drying, gelling and final curing. The temperature, controlled by DC resistive heating is maintained for a given period for each step.

Abstract: A method of assembling a coil includes forming a ferrite core having a top end, a bottom end, an inner opening extending from the top end to the bottom end, a cylindrical outer surface, and a step portion formed near the bottom end, the step portion extending past the outer surface. A first high dielectric material is applied on the outer surface of the ferrite core, then a conductive wire is wound onto the high dielectric material, whereafter a second high dielectric material is applied over the conductive wire.

Abstract: The magnetic core of an inductive device is formed of a plurality of wires that extend through the inductive device, and beyond the electric winding. The ends of the wires are formed around the electric winding, meet, and are connected together enveloping the magnetic core and windings forming a complete magnetic circuit. The inductive device may be a transformer with two or more windings, a choke coil with only one winding, or other inductive device. The electric windings may be wound directly onto the wire magnetic core, or may be formed separately and then placed on the magnetic core. A mounting post or the like may be bound into the core and used as a mount for the inductive device; and, cooling tubes and/or large rods for support may be incorporated into the core.

Abstract: A magnet wire having differential build insulation for use in transformer coils is disclosed. The wire has a rectangular conductor with an insulation that is thicker on the top and bottom surfaces of the wire than it is on the sides. With the thicker coating on the top and bottom, the wire can be used in layer wound distribution transformer coils, both high voltage wire wound coils and low voltage wound coils, without needing additional insulation between the layers of the winding.

Abstract: A method for producing a flat coil of cable coiled into a single layer coil comprising the steps of: holding an end of the cable; tautening the cable; tight-coiling the total length of the flat cable in spiral around itself, maintaining a spiral form and avoiding the unwinding of the cable; attaching holding means around the flat coil once the total length of the cable is coiled in order to maintain the stiffness of the flat coil.

Abstract: A wire wound electronic component includes a bobbin having a core 1a having a substantially circular cross-section and rectangular flanges 1b formed at both ends of the core. A groove 2 is formed in each side of each flange 1b. A conductive film or external electrode 3 is formed on each flange 1b. A coil or wire 4 is wound round the core 1a and has a conductor protruding from opposite stripped ends thereof. The opposite ends 5 of the conductor are respectively received in the grooves 2 of the flanges 1b and connected to the conductive films 3. A coating or armor 6 is formed on the coil 4 and has a flat surface 6a. The coating 6 has a rectangular configuration complementary to the configuration of the flanges 1b.

Abstract: A dry-type power distribution transformer has a generally rectangular, wound amorphous metal core and a resin encapsulated, generally rectangular coil. The core has a generally rectangular core window within which is located a substantially straight section of the coil. When assembled to form a power distribution transformer, the shape of the coil's substantially strait section conforms to the shape of the core window. The transformer is inexpensive to manufacture, exhibits low resistivity and low core loss, and is light weight, compact and reliable in operation.

Abstract: A magnetic device and a method of manufacture therefor. In one embodiment, the magnetic device includes: (1) a bobbin having a winding guide and molded-in margins proximate opposing inside flanges of the bobbin, each of the opposing inside flanges having at least one notch formed in an inside face of each of said opposing inside flanges; (2) an inner winding wound about the winding guide and between the molded-in margins; (3) an outer winding wound about the inner winding and the winding guide and between the flanges; and (4) an insulating plate, provided in the at least one notch and interposed between the inner and outer windings, a thickness of the insulating plate providing a predetermined creepage distance between at least one lead of the inner winding and the outer winding.

Abstract: In an independent ignition type ignition coil for an internal combustion engine which is used being directly coupled to a corresponding ignition plug, a center core 1, a secondary coil 3 wound around a secondary coil bobbin 2 and a primary coil 5 wound around a primary coil bobbin 4 are arranged concentrically in a coil casing 6 in this order from the inside thereof and such as epoxy resin 8 and soft epoxy 17 are filled between these constituting members, wherein on the outer surface of the primary coil 5 a cover film which promotes peeling off thereof from the epoxy resin 8 is formed, and because of existence of these peeling off portions between the primary coil 5 and the epoxy resin 8 and between the layers of the primary coil 5, a stress component induced inside the secondary coil bobbin 2 due to heat contraction difference between the primary coil 5 and the secondary coil bobbin 2 among thermal stress induced inside the secondary coil bobbin 2 is reduced.

Abstract: An improved transformer coil of the type characterized as a shell-form or pancake coil used in large scale power transmission transformers. The improvement adds strength to resist lateral edge coil deformation as a result of handling the coil during transformer assembly and as a result of fault current surges. The improvement is directed to tightly spread tapeing some of the inner and outermost conductor turns together with preferably a heat shrinkable structural tape. This spread tapeing is periodic or spaced along the outer periphery of the coil for economy and may be staggered in terms of the number of conductor turns wrapped together. Preferably, the innermost conductor turns may also be spread taped in this same manner.

Abstract: This invention relates to the resin encapsulation of solenoids to achieve water resistance at pressure depth. When a compatible and bondable resin is used to form a solenoid bobbin, to insulate the lead-in wires and to encapsulate the solenoid, the resulting encapsulation is effective in resisting water penetration. The formation of bonds between the encapsulation and the solenoid bobbin flanges and insulated lead-in wires allows the encapsulated solenoid to resist water penetration and to operate efficiently in underwater environments.

Abstract: A transformer and method of making a transformer is disclosed. The transformer has a magnetic core, a first winding and a second winding. The first and second windings are wound about the core, and an insulating jacket, which includes a plurality of protrusion, mounted about the core. One of the first and second windings is wound about the insulating jacket. The core is preferably a toroid core in one embodiment. Some of the anchors are on the inner diameter of the insulating jacket, and other on the outer diameter of the insulating jacket. The anchors are preferably spaced at equal circumferential positions. The windings are a progressive windings, with various sections, and each section has a number of layers. Each progressive section is anchored by at least two of the anchors. The first and second windings are wound directly on the core insulation, and the insulating jacket is mounted directly on the core.