Abstract: The invention relates to a transformer tank generally shaped like a rectangular prism and filled with insulating liquid and assembled mainly by welding. The tank comprises a detachably fastened transformer cover plate and a transformer core placed in the transformer tank while the cover plate is detached. In accordance with the invention, at least one of the substantially vertical walls of the transformer tank comprises a detachable wall portion whose detachment allows the transformer core to be removed from the transformer tank through an opening formed by the detachment of the wall portion. In this way the transformer can be repaired on site without having to lift the transformer core from the transformer tank in the conventional manner, which would require free space above the transformer.

Abstract: A transformer container comprising a transformer tank having a bottom, a front forward panel, two side panels, a rear panel and a top panel. The top panel forms a rim defining a portal for accessing to the interior of the transformer tank. The transformer tank is supported on a pad. A transformer sill is connected to and supported on the pad and is connected to the transformer tank adjacent the front panel. A transformer door is pivotally connected to the top panel of the transformer tank. The transformer door is supported on the transformer sill and may be locked thereto in a closed position. The transformer door, the pad and the transformer tank form an enclosure. The top panel of the transformer tank defines a plurality of holes. The front panel of the transformer tank is connected to the top panel of the transformer tank between the holes and the access portal, thus the holes communicate with the enclosure and not the interior of the transformer tank.

Abstract: A device for electrically interconnecting and packaging electronic components. A non-conducting base member having a component recess and a plurality of specially shaped lead channels formed therein is provided. At least one electronic component is disposed within the recess, and the wire leads of the component are routed through the lead channels. A plurality of lead terminals, adapted to cooperate with the specially shaped lead channels, are received within the lead channels, thereby forming an electrical connection between the lead terminals and the wire leads of the electronic component(s). The special shaping of the lead channels and lead terminals restricts the movement of the lead terminals within the lead channels in multiple directions during package fabrication, thereby allowing for the manufacture of larger, more reliable devices.

Abstract: A toroidal transformer for a communications application where a first winding is wound on the core. A separator comprising a pair of annular-shaped cups then encloses the core and first winding. A second winding is wound on the outer surface of the separator. The separator, fabricated from a low K material, provides substantial reduction in the capacitance between the first and second winding.

Abstract: A coil spool for a ventilated solenoid valve includes a proximal end cap and a distal end cap. Each end cap defines an outer periphery and an inner periphery. Moreover, each end cap includes plural teeth extending from its outer periphery. Plural ribs extend from the inner periphery of the proximal end cap to the inner periphery of the distal end cap. A wire is wound around the spool to form a coil and the spool is installed in a coil case such that the teeth cooperate with the coil case to establish plural outer ventilation passageways. A plunger guide is installed within the spool such that the ribs cooperate with the plunger guide to establish plural inner ventilation passageways. The ventilation passageways allow air to communicate with the coil in order to cool the coil.

Abstract: An ignition coil for motor vehicles with a single output terminal comprises a body (16) carrying at one of its ends a flexible cap (18) provided with a seat (24) designed to receive an end (10) of a spark plug. The cap (18) comprises a high-voltage terminal (38, 40) electrically connected to the high-voltage winding of the coil and provided with a connection portion designed to receive a terminal (14) of the plug (10). A diode (26) is housed inside said cap (18) and is connected in series between two portions (38, 40) of said high-voltage terminal.

Abstract: An ignition coil contains an elongated substantially circular coil core which includes a primary coil and a secondary coil each disposed radially outwardly of the core with the core composed of a plurality of generally rectangular elements at least some of which have a different width than others and the elements being in surface-to-surface contact with each other. The lateral walls of the elements may have a shape which is not perpendicular to the longitudinal extent of the elements. The core may be welded at its ends. A core contained within this ignition coil, which may be an automotive ignition coil, is disclosed.

Abstract: A transformer device includes a housing made of a dielectric material, a core received within the housing, a secondary coil wound around an outer peripheral surface of the core, a high-voltage terminal connected to a high-voltage side end of the secondary coil and a primary coil electromagnetically coupled with the secondary coil. The housing has an open axial end and a closed axial end. The high-voltage side end of the secondary coil is positioned within the housing adjacent to the closed end of the housing. A high-voltage generating apparatus includes the transformer device received within a metal case. A discharge lamp lighting system includes the high-voltage generating apparatus and a discharge lamp electrically connected to the high-voltage generating apparatus.

Abstract: Disclosed are a method of manufacturing a wiring member, and an electric connection box manufactured by retaining the manufactured wiring member in a case. The method comprises the steps of winding an electric wire around a wire winding body having a plurality of wire holding members arranged thereon, and wiring the electric wire into a desired pattern using a plurality of retaining sections formed on each of the wire holding members; cutting the electric wire at a desired position; and removing the electric wire at least from the wire winding body.

Abstract: A method of manufacturing a coil unit includes the first step of disposing a coil between a first frame and a second frame, the second step of pouring liquid resin into between the first frame and the second frame with the coil disposed therebetween, and the third step of curing the liquid resin to thereby fix the first frame, the second frame and the coil to one another.

Abstract: An inductive component intended to be installed on a printed circuit includes at least one winding, a body, and a magnetic core. The winding is made of an electrically conductive wire wound to form a flat coil the ends of which are connected to the inner ends of connecting terminals. The body is formed from a block of insulating material over-moulded onto the coil and onto the said inner ends of the terminals, the body including a central opening which passes through the body along the axis of the coil. The magnetic core is made of a ferrite layer that surrounds the body in a center plane containing the axis of the coil. A center element passes through the opening in the body.

Abstract: In order to prevent a crack of plastic parts caused by a shrinkage force of a resin filler filled in an ignition coil casing, a cylindrical coil casing houses a primary coil and a secondary coil concentrically, and the resin filler such as epoxy resin is filled in the coil casing to insulate between the parts in the coil casing and to fix the parts. A ring-shaped partition member is provided at the upper portion in the coil casing to separate the resin filler locating above the primary coil and the secondary coil inside and outside. The partition member is made of a resin whose adhesive strength against the resin filler is weak, such as polypropylene (PP). The partition member reduces the shrinkage force between the outside resin filler and the inside resin filler, and prevents a crack of plastic parts, such as the secondary spool.

Abstract: An ignition coil for motor vehicles, comprising: a magnetic core (12) having a rectilinear axis; a secondary spool (16) supporting a high-voltage winding (18) and being set coaxially with respect to the magnetic core (12); a primary spool (20) supporting a low-voltage winding (22) and being set coaxially with respect to the secondary spool (16) and outside the latter; a tubular-shaped outer casing (24) which encloses the assembly comprising the magnetic core (12) and the spools (16, 20); and a low-voltage connector (28) including a connector body (30) made of plastic material and a plurality of metal contacts (32) fixed to the connector body (30). In the ignition coil, the connector body (30) is made of a single piece with the primary spool (20).

Abstract: The invention describes a control unit of a valve mechanism with an electromagnetic coil (1) where the electromagnetic coil (1) is electrically and mechanically connected to the control unit via a connection device which has an electrically conducting spring-mounted connecting ridge (10).

Abstract: A coil-embedded dust core and a method for manufacturing the coil-embedded dust core are provided. The coil-embedded dust core comprises a coil formed from a flat conductor wound in a coil configuration, and a green body consisting of insulating material-coated ferromagnetic metal particles. This results in a coil-embedded dust core more compact in size but with larger inductance. A rectangular wire can be used as the flat conductor. In addition, parts of the coil may function as terminal sections. In this case, the terminal sections of the coil may be formed wider than other part of the coil. The coil-embedded dust core is less prone to joint failures between a coil and terminal sections and to insulation failures of the coil and the terminal section with respect to the magnetic powder. The coil-embedded dust core is more compact while achieving larger inductance.

Abstract: A stick-type ignition coil device has a central core, and primary and secondary windings wound concentrically around the central core in a coil casing. A positioning part is provided in the casing to define the position of the central core. An insulating resin such as epoxy resin is filled in the coil casing for electrical insulation and fixing of components in the coil casing. A thermal stress releasing member, which is less adhesive to and easily peelable from the insulating resin, is provided on the upper surface of the positioning part. The thermal stress releasing member is separated from the insulating resin and allows the positioning member to move with the central core, thereby minimizing cracks which will occur in the insulating resin formed between the central core and the positioning part.

Abstract: A coil part which is obtained by sealing at least part of the periphery of a coil with a conductor wound on a bobbin with a high heat-conductive and magnetism-impermeable resin composition, and can efficiently guide out a magnetic flux generated to the outside and efficiently radiate heat generated to the outside.

Abstract: A starter motor for an internal combustion engine has an inertia type pinion mechanism and an axial solenoid 34 which is arranged to prevent pump out of the pinion 48 during start up of the engine.

Abstract: A method for making a high current, low profile inductor includes a wire coil having an inter coil end and an outer coil end. A magnetic material completely surrounds the wire coil to form an inductor body. First and second leads connected to the inner coil end and the outer coil end respectively extend through the magnetic material to the exterior of the inductor body. The method of operation involves pressure molding the magnetic material around the wire coil.

Abstract: An ignition coil device, which is mounted in a plug hole of an internal combustion engine, comprises a primary coil 1 wound to have larger diameter, a secondary coil 2 wound on a bobbin 2A and disposed inside the primary coil 1, an iron core 3 disposed inside the bobbin 2A, and a shielding case 10 disposed around the primary coil 1, a gap between the primary coil 1 and the secondary coil 2 being filled with an insulating resin 12. The primary coil 1 is made bobbinless so as to secure and increase the withstand voltages of the primary coil and the secondary coil.

Abstract: A line interface transformer having a transformer core disposed in an off center cavity formed in the transformer housing. Line side interface terminals are located on one side of the housing and chip side terminals are located on an opposite side with the cavity being located closer to the chip side terminals than to the line side terminals. The transformer core has a line side winding and a chip side winding with the line side winding being made of a double insulated wire.

Abstract: An ignition coil which directly distributes the high voltage to an ignition plug, includes a case, a central iron core, a secondary coil in which a secondary copper wire is coaxially wound around the central iron core, being housed in the case, a primary coil in which a primary copper wire is wound around the outside of the case, and a sheath iron core arranged outside the primary coil.

Abstract: A container (2) with an oil immersed core (1) and windings has corrugated walls. Bushing insulators (9,10) have pressure-resistant and water-resistant cable shoes (11). A tank encompasses another container (4) filled with insulating oil (3) and has pressure-resistant cable bushing (13) and connectors for electrical connections of the transformer.

Abstract: An ignition coil assembly is disclosed for a spark plug of the type used in internal combustion engines. The ignition assembly includes a housing, a tubular and cylindrical primary coil, and a tubular and cylindrical secondary coil. The primary and secondary coils are each wound on their individual bobbins and the bobbins are mounted in the housing such that the primary coil is coaxially positioned inside the secondary coil. The ignition coil assembly further includes a magnetic core having a first portion which extends through the interior of both the primary and secondary coil and a second portion which extends exteriorly of the primary and secondary coils. The first portion of the coil is substantially circular in cross sectional shape thus matching the circular interior of the primary bobbin. In order to construct the primary coil and secondary coil subassembly, the primary bobbin is first positioned on a winding machine and the primary wire is wound on the bobbin.

Abstract: An individual ignition type ignition coil device for engine which is directly connected to each spark plug for use, comprises a coil case 6, and a center core 1, a secondary coil 3 wound on a secondary bobbin 2 and a primary coil 5 wound on the primary bobbin 4 each concentrically installed inside the coil case 6 in turn from the inside to the outside. Insulating resin 17, 8 is filled between the interiorly installed structural members. The secondary bobbin is made of material of modified PPO mixed with inorganic matter of 30% or more.

Abstract: In a discharge lamp apparatus for a vehicle, it is determined that a grounded condition is present when a lamp voltage is less than a predetermined voltage and a lamp current is less than a predetermined current. Electric power supply to the lamp is stopped temporarily in response to the determination of the grounded condition, and then the lighting operation is restarted again. If the grounded condition is determined again, the above operation is repeated. If this repetition continues for a predetermined period, the lighting operation is disabled continuously. In controlling the lamp, a voltage of a battery is boosted by a voltage booster transformer, which is turned on and off by a MOS transistor so that electric power supplied to the lamp is duty-controlled. An upper limit is set to the duty ratio, and the upper limit is increased as the lamp current decreases, so that the lighting characteristics of the lamp is improved.

Abstract: An ignition apparatus includes a suppression device comprising a suppression winding that is in series with the secondary winding and is further located outside of a magnetic circuit. The suppression winding is made from the same wire as used in the secondary winding and is wound on a reduced diameter portion of a secondary winding spool. A carbon resistor is disposed in series with the suppression winding in another embodiment. Nickel wire may be substituted for the suppression winding and carbon resistor in order to obtain both inductance and resistance characteristics for the suppression device.

Abstract: A transformer including a bobbin formed by uniting a winding member, which has a primary winding and secondary winding and a bore formed thereon and therein, with a primary winding fixture and secondary winding fixture adjoining the openings of the bore, and a ferromagnetic core having a core portion thereof inserted into the bore and including an enclosure for enclosing the windings is manufactured according to a process including an affixing step of firmly affixing both or either of the primary winding fixture and secondary winding fixture to the ferromagnetic core, an impregnation step of impregnating the transformer with a varnish, and an applying step of applying adhesives.

Abstract: An ignition apparatus includes a central core, a primary winding, a secondary winding wound on a secondary winding spool, a case and a shield. The primary winding is covered with a release layer comprising one of PTFE, polyamide, polyester or silicone rubber material. The release layer is configured to demote adhesion of an encapsulant disposed between the release layer and an inside diameter of the secondary winding spool. The encapsulant adheres more consistently and completely to the secondary winding spool reducing localized stresses on the spool which otherwise cause cracking or the like to occur.

Abstract: A transformer includes a tank having a side wall, a core defining a core window, and a pair of coils, each of which surrounds a portion of the core and includes a portion passing through the core window. The transformer further includes a core and coil support member that extends through the core window to support the core and coils. The core and coil support member includes an upper flange and a lower flange, each flange having a channel formed along an outer surface of the flange that conforms in shape to an inner surface of the core. The core and coil support member includes a web that extends between and connects the upper and lower flanges, the web including first and second ends that extend out from the flanges. The transformer includes a support bracket that attaches to the side wall of the tank, and centers and supports the core and coil support member. The support bracket includes three sides that define a channel through which an end of the core and coil member extends.

Abstract: A method for forming a resin molding on a coil of a transformer is disclosed. The method comprises the steps of inserting a coil into an auxiliary spacing apparatus, inserting the auxiliary spacing apparatus into a mold, and forming a resin molding for the auxiliary spacing apparatus with the coil by putting a resin into the mold. According to the methods, the coil is not damaged and a resin molding is formed with an uniform thickness.

Abstract: The subject of the invention is an ignition coil, of the type intended to be mounted on a spark plug for the individual electrical supply of this spark plug, comprising an internal secondary winding (2), an external primary winding, a flux return shell (9) and a casing (4). According to the invention, the said casing (4) surrounds only the secondary winding, the primary winding being wound onto the casing, on the outside of the latter; and being itself surrounded by the flux return shell.

Abstract: A current transformer for a ground fault circuit breaker used on a circuit having at least one line conductor and a neutral conductor includes a toroidal core having a circular opening defining a center point and a multi-turn winding wound on the core. A first guide member is disposed on one side of the core, and a second guide member is disposed on another side of the core. The first and second guide members each have a hole for receiving the line conductor and a hole for receiving the neutral conductor formed therein. The guide members thus position the conductors with respect to the core. Also included is a method of correcting asymmetries in the current transformer. The method includes measuring the magnitude and orientation of any asymmetries, and then altering the current transformer based on the measured magnitude and orientation of the asymmetries so as to eliminate the asymmetries.

Abstract: A device for electrically interconnecting and packaging electronic components. A non-conducting base member having a component recess and a plurality of specially shaped lead channels formed therein is provided. At least one electronic component is disposed within the recess, and the wire leads of the component routed through the lead channels. A plurality of lead terminals, adapted to cooperate with the specially shaped lead channels, are received within the lead channels, thereby forming an electrical connection between the lead terminals and the wire leads of the electronic component(s). The special shaping of the lead channels and lead terminals restricts the movement of the lead terminals within the lead channels in multiple directions during package fabrication, thereby allowing for the manufacture of larger, more reliable devices.

Abstract: A mounting apparatus for an electromagnetic device such as a transformer of inductor includes a generally planar metallic plate as a first heat sink, and a metallic mounting cup as a second heat sink. The mounting cup includes a cavity configured to receive the electromagnetic device, the cavity being defined by a base, and an axially-extending annular sidewall extending from the base to a flange portion of the mounting cup. The mounting cup includes first and second passages for allowing the leads of first and second windings of the electromagnetic device to be routed out of the cavity. The cavity is filled with a polyurethane potting resin, and the mounting cup, including the potted electromagnetic device, is mounted to the plate heat sink using fasteners. The mounting cup, which surrounds the electromagnetic device, in combination with the potting resin provides improved thermal transfer to the plate heat sink, as well as providing resistance to vibration and shocks.

Abstract: A current transformer for a ground fault circuit breaker used on a circuit having at least one line conductor and a neutral conductor includes a toroidal core having a circular opening defining a center point and a multi-turn winding wound on the core. A first guide member is disposed on one side of the core, and a second guide member is disposed on another side of the core. The first and second guide members each have a hole for receiving the line conductor and a hole for receiving the neutral conductor formed therein. The guide members thus position the conductors with respect to the core. The present invention also includes a method of correcting asymmetries in the current transformer. The method includes measuring the magnitude and orientation of any asymmetries, and then altering the current transformer based on the measured magnitude and orientation of the asymmetries so as to eliminate the asymmetries.

Abstract: A current transformer for a ground fault circuit breaker used on a circuit having at least one line conductor and a neutral conductor includes a toroidal core having a circular opening defining a center point and a multi-turn winding wound on the core. A first guide member is disposed on one side of the core, and a second guide member is disposed on another side of the core. The first and second guide members each have a hole for receiving the line conductor and a hole for receiving the neutral conductor formed therein. The guide members thus position the conductors with respect to the core. Also included is a method of correcting asymmetries in the current transformer. The method includes measuring the magnitude and orientation of any asymmetries, and then altering the current transformer based on the measured magnitude and orientation of the asymmetries so as to eliminate the asymmetries.

Abstract: The invention relates to a transformer tank generally shaped like a rectangular prism and filled with insulating liquid and assembled mainly by welding. The tank comprises a detachably fastened transformer cover plate and a transformer core placed in the transformer tank while the cover plate is detached. In accordance with the invention, at least one of the substantially vertical walls of the transformer tank comprises a detachable wall portion whose detachment allows the transformer core to be removed from the transformer tank through an opening formed by the detachment of the wall portion. In this way the transformer can be repaired on site without having to lift the transformer core from the transformer tank in the conventional manner, which would require free space above the transformer.

Abstract: A housing for an electronic component has a set of walls for surrounding the component. The component is snap-fitted into the housing to retain it in the housing through snap-fit features in the housing and snap-fit features on the component. The housing can incorporate springs which, in use, bias the component into contact with the snap-fit features. If the component is a transformer, the springs can act on the transformer laminations to press the stack of laminations together while biasing the component into contact with the snap-fit features.

Abstract: It is intended to provide a non-contact transformer which simplifies attachment work, causes no sound of rubbing between wires or resistance during steering wheel manipulation, increases the transmission efficiency, and can be manufactured easily by virtue of a minimized warp occurring during manufacture of a core. A non-contact transformer is provided that includes two disc-shaped magnetic cores (19) each having at least one concentric and radial groove (21), and a magnetic sleeve (25) having a cylindrical shape or a pot shape having an opening at the center of the bottom surface. The two magnetic cores are opposed to each other with a predetermined distance left therebetween in a space enclosed by the magnetic sleeve. A wining (23) of wire is accommodated in the at least one concentric groove. Each of the magnetic cores is a combination of a plurality of fan-shaped partial cores (27) to be formed in a disc shape.

Abstract: An insulating resin is made containing an epoxy system of epoxy resin: and an epoxy diluent, with a phenolic accelerator selected from catechol or pyrogallol and an organotin latent catalyst selected from triphenyltin chloride, tribenzyltin chloride, tribenzyltin hydroxide or triphenyltin acetate. The insulating resin is solventless and has a viscosity of from 10 centipoise to 450 centipoise at 25° C. for up to eight weeks and can be used as an impregnating resin in slot portions (15) and 16of an electrical coil (10), usually in combination with mica tape, in a motor (20) or a generator (30).

Abstract: An encapsulated magnet assembly comprises a non-metallic housing and a magnet disposed within a housing magnet chamber. A housing end cap is fuse bonded to the housing to encapsulate the magnet therein and form an air and fluid-tight seal with the housing. An insulating spacer is interposed between an exposed surface of the magnet and the end cap before assembly and fuse bonding, and is formed from a thermally insulating material to prevent the transmission of thermal energy to the magnet during the fuse bonding process. The insulating spacer serves to protect the magnet from unwanted thermally induced magnetic field losses. The housing also includes one or more projections that extend into the magnet chamber and that cooperate with complementary grooves in the magnet to prevent the magnet from rotating within the chamber.

Abstract: An angular pin is used in a connecting portion of each component, and a plated copper wire for electrical connection of the component is wound at several turns around the angular pin.

Abstract: An ignition coil for an internal combustion engine is mainly made up of a transformer part and a control circuit part and a connecting part, and the transformer part is made up of a iron core which forms an open magnetic path, magnets, a secondary spool, a secondary coil, a primary spool and a primary coil. By respectively setting the cross-sectional area SC of the iron core between 39 to 54 mm2, the ratio of the cross-sectional area SM of the magnets with the cross-sectional area SC of the iron core in the 0.7 to 1.4 range, the ratio of the axial direction length Lc of the iron core with the winding width L of the primary and secondary coils in the 0.9 to 1.2 range, and the winding width L in the 50 to 90 mm range, the primary energy produced in the primary coil can be increased without increasing the external diameter A of the case.

Abstract: A wire-wound inductor includes a substantially square-flanged core member and a case core member. The substantially square-flanged core member includes an upper substantially square flange and a lower substantially square flange. The substantially square-flanged core member, around which a coil is wound, is inserted into the case core member, and the upper flange of the substantially square-flanged core member is fitted in an opening of the case core member. A planar corner abutment surface is provided at each of the four corners of the inner surface of the substantially square opening, and the corners of the upper flange abut the respective planar corner abutment surfaces.

Abstract: An ignition coil for motor vehicles with a single output terminal comprises a body (16) carrying at one of its ends a flexible cap (18) provided with a seat (24) designed to receive an end (10) of a spark plug. The cap (18) comprises a high-voltage terminal (38, 40) electrically connected to the high-voltage winding of the coil and provided with a connection portion designed to receive a terminal (14) of the plug (10). A diode (26) is housed inside said cap (18) and is connected in series between two portions (38, 40) of said high-voltage terminal.

Abstract: An electronic surface mount package provides a one piece construction package (with an open bottom) with one or more terminal pins molded into the package. Each of the pins have a notched post upon which a wire is wound which is from a toroid transformer carried within the package. Each of the posts are notched so their respective wires are separate from one another so as to prevent arcing. The case is opened at the bottom which prevents harm from expansion or cracking.

Abstract: A stick-type ignition coil device has a central core, and primary and secondary windings wound concentrically around the central core in a coil casing. A positioning part is provided in the casing to define the position of the central core. An insulating resin such as epoxy resin is filled in the coil casing for electrical insulation and fixing of components in the coil casing. A thermal stress releasing member, which is less adhesive to and easily peelable from the insulating resin, is provided on the upper surface of the positioning part. The thermal stress releasing member is separated from the insulating resin and allows the positioning member to move with the central core, thereby minimizing cracks which will occur in the insulating resin formed between the central core and the positioning part.

Abstract: In a stick-type ignition coil device for engines, a primary spool is disposed outside a secondary coil. The primary spool is made of PBT (polybuthylene telephthalate) having a low melting viscosity and a high flowability as a resin base material. The resin base material is admixed with an olefin rubber in 5 wt. %, glass fibers in 12.5 wt. % and silica in 12.5 wt. %. A primary coil 24 comprises a wire body coated with PET (polyethylene telephthalate), silicone or wax as a separating member, and is wound around the primary spool. The growth of trees in the primary spool 23 restricted even when electrical discharges occur between a secondary coil and the primary coil and the primary spool is eroded by the electrical discharges, because silica is added in the primary spool.

Abstract: An ignition coil for an internal-combustion engine has satisfactory electrical insulation capacity and is excellent in reliability and durability. The ignition coil for an internal-combustion engine comprises a primary bobbin on which a primary coil is wound, a secondary bobbin on which a secondary coil is wound, and a center core. The area of a cross section of the center core perpendicular to an axis of the coils at a position on the inner side of the opposite ends of the center core is a maximum.