Abstract: An ignition apparatus includes a high voltage (HV) terminal formed of stamped sheet metal attached to a secondary winding spool, and to which a high voltage end of the secondary winding is soldered. The ignition apparatus further includes an electrically conductive cup formed of stamped aluminum or brass that is disposed in a case and is configured to receive the high voltage terminal when the secondary winding spool is inserted in the case. The high voltage terminal has a spring tab or the like that is biased radially outwardly into engagement with an inner annular surface of the cup. A bottom outer surface of the cup is arranged to be engaged by a high voltage spring or the like for making the connection to the spark plug. The cup is substantially free of burrs, sharp edges, and the like, and therefore reduces localized occurrences of high electric field concentrations, which could otherwise lead to insulating material, and thus ignition coil, failure.

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: 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 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: 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: The invention concerns an air-core primary voltage winding comprising a conductive wire coil coated with an insulating sheath, characterized in that said coil (1) is encapsulated in a high voltage insulating thermoplastic resin (2), and in that it further comprises an electroconductive potential fixing surface layer (3) in thermoplastic resin compatible with the thermoplastic resin of the insulating encapsulation (2), deposited on this encapsulation.

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: 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: In accordance with the invention, a low profile magnetic device comprises a crelenated ferrite body having first and second conductive paths winding around the body. Current applied to one of the conductive windings can adjust the threshold current level in the other conductive winding at which the inductance characteristic changes to a relatively constant inductance.

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: One of the objectives of the present invention are to provide smaller, lighter and less expensive structure in a starting device for discharge lamp for car use so as to prevent breakage due to vibrations etc . . . And another objective is to attain simultaneous electrical and structural connections between a high voltage electrode and a coil of a starting transformer. The device having the following constitution realizes the above-mentioned objectives. A starting device for a discharge lamp comprises a socket equipped with a high voltage electrode and a grounding electrode, a bobbin with a core-less structure, a starting transformer comprising a primary coil and a secondary coil wound around the bobbin. A screw electrode is arranged at the center of the end face of the bobbin. One end of the screw electrode is connected to an output terminal of the high voltage side of the secondary coil on the starting transformer.

Abstract: A center core 1, a secondary coil 3 wound at a secondary bobbin 2 and a primary coil 5 wound at a primary bobbin 4 are placed concentrically inside a coil case 6 in sequence from the inside of the coil case. One end of the secondary coil 3 is connected to the primary coil side and becomes a low-voltage side, and the other side becomes a high-voltage side due to an induced voltage and used with connection to the individual ignition plugs of the internal combustion engine. The radial thickness of the bobbin at the low-voltage side 3a and the high-voltage side 3c of the secondary coil, each located at the both ends of the secondary coil, is made larger than the radial thickness of the bobbin at the center part 3b of the secondary coil. The radial thickness of an insulating layer 8 between the secondary coil 3 and the primary coil 5 at the low-voltage side 3a of the secondary coil is smaller and the radial thickness of the insulating layer at the high-voltage side 3b of the secondary coil is larger.

Abstract: An inductor which has a superior shape retaining property of a coil conductor, is superior in mass-productivity, and can be applied to an automated manufacturing line, and a manufacturing method therefor are provided. The surface of a metal wire provided with an insulating film thereon is coated with a thermal melting resin. The thickness of the thermal melting resin is, for example, approximately 1 &mgr;m. As the thermal melting resin, a thermoplastic resin or a thermosetting resin, such as a polyimide resin or an epoxy resin, containing 85 wt % of a powdered ferrite is used. This coated metal wire is densely wound to form a solenoid-type coil conductor. Next, the thermal melting resin is softened by a heat treatment at, for example, 180° C. and is then solidified by spontaneous cooling. Accordingly, the portions of the coil conductor adjacent to each other are bonded together by the thermal melting resin.

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 super-thin surface-mounting-type coil component, for mounting on a hybrid IC such as a DC-DC converter, is provided. Such a surface-mounting-type component comprises a core having a flat core portion in which the ratio of thickness to width (t/w) is not greater than 1/3, flange portions extending from both ends of the core portion in a longitudinal direction to be integrated with the core portion, two or four electrode layers spacedly positioned apart from each other and formed on peripheral portions, including side surfaces of the flange portions in at least a vertical direction, of the flange portions of the core. A winding is wound on the core portion of the core, having both ends obliquely led from the side surfaces of the flange portions and conductively fixed to the electrode layers of the side surfaces by thermo-compression bonding.

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 magnetic element including: a composite magnetic member A containing a metallic magnetic powder in an amount of 50-70 vol. % and a thermosetting resin in an amount of 50-30 vol. %; a magnetic member B that is at least one selected from a ferrite sintered body and a pressed-powder magnetic body of a metallic magnetic powder; and a coil. The magnetic element is characterized in that a magnetic path determined by an arrangement of the coil passes the magnetic member A and the magnetic member B in series and the coil is embedded in the magnetic member A. The present invention also provides a method for manufacturing the magnetic element.

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: An ignition coil is provided. The ignition coil comprises a casing, a plurality of pins and a bobbin. The pins are disposed inside the casing. The bobbin, having a plurality of first terminals corresponding to the pins respectively, is disposed inside the casing. Each of the first terminals is provided with a ring-shaped portion in contact with the corresponding pin. Hence, resin, filled in the ignition coil, is prevented from leaking out of the casing.

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: The present invention provides a flyback transformer comprising a core, a low-voltage bobbin and a conductive device. The core comprises an upper core and a lower core. The low-voltage bobbin comprises a skirt. The skirt has a lower opening for receiving the lower core and a grounding pin is provided on a side portion of the skirt. The conductive device comprises an U-shaped body, an input end and an output end. The U-shaped body is engaged with the side portion of the skirt. The input end is provided on one end of the U-shaped body for flexibly connecting the lower core. The output end is provided on the other end of the U-shaped body for connecting the grounding pin. The core is grounded by the way of connecting the lower core and the grounding pin through the conductive device.

Abstract: A detachable transformer includes a high-voltage coil, an anti-splash cap, a low-voltage coil and a transformer body. The coupling chamber has a top end coupled to the anti-splash cap and a bottom end for matching the transformer body. It is assured that the filler can be encapsulated between the high-voltage coil and the transformer body. After the low-voltage coil and the iron core are inserted, the transformer is then formed. Furthermore, the anti-splash cap can be either separable from the coupling chamber or an integral part of the high-voltage coil. The anti-splash cap can also be replaced by an anti-splash sleeve, which is disposed in the high-voltage coil. This enhances the insulation effect of the high-voltage coil by encapsulating the filler in the gap and between the high-voltage coil and the transformer body.

Abstract: To improve an anti-heat shock performance and an electric field concentration relaxation (an insulation performance) between a secondary coil and a center core, to attain a narrow diameter structure in an individual ignition type ignition coil and further to improve an assembling working of the ignition coil. The individual ignition type ignition coil is adopted to an engine having a plastic head cover. A secondary coil 3 is positioned at an inner side of a primary coil 5 and between a secondary bobbin 2 and a center core 1 a soft epoxy resin 17 is filled up. In the secondary bobbin 2, a secondary coil low voltage side is a potting side of the soft epoxy resin 17 and an inclination having a difference in an inner diameter is provided on the inner diameter in which the secondary coil low voltage side is formed large and secondary coil high voltage side is formed small.

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: The present invention provides a low profile inductor and a method of making the same. First, a core seat including a cavity and two openings is provided. Then, a flat coil is embedded in the cavity of the core seat. The flat coil includes a first terminal and a second terminal extending outward or revealed by the openings so as to serving as the pins of the inductor. Further, a core cover is formed on the flat coil and the core seat.

Abstract: A center core 1, a secondary coil 3 wound at a secondary bobbin 2 and a primary coil 5 wound at a primary bobbin 4 are placed concentrically inside a coil case 6 in sequence from the inside of the coil case. One end of the secondary coil 3 is connected to the primary coil side and becomes a low-voltage side, and the other side becomes a high-voltage side due to an induced voltage and used with connection to the individual ignition plugs of the internal combustion engine. The radial thickness of the bobbin at the low-voltage side 3a and the high-voltage side 3c of the secondary coil, each located at the both ends of the secondary coil, is made larger than the radial thickness of the bobbin at the center part 3b of the secondary coil. The radial thickness of an insulating layer 8 between the secondary coil 3 and the primary coil 5 at the low-voltage side 3a of the secondary coil is smaller and the radial thickness of the insulating layer at the high-voltage side 3b of the secondary coil is larger.

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 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: Comparing a conventional ignition coil, both the height and the width become compact and only one type can be used in substitution for a conventional multiple type of the ignition coil. Furthermore, it may be mounted in a severe layout limited by the width and the height. Accordingly, it allows the cost to be greatly reduced by reducing the kind of the press mold for case and investment for the equipment, and reducing the labor cost for a production process and increasing a production quantity for each piece of equipment. An ignition coil for an internal combustion engine includes: an actuated magnetic portion 1b of an iron core 1 which has an axis line crossing an ignition plug axis line of the internal combustion engine at a right angle and around which a primary coil 2 is wound; and a switching unit 4 which is disposed at an end of the actuated magnetic portion 1b vertically to the axis line of the actuated magnetic portion 1b and flows and intercepts a primary current flowing through the primary coil 2.

Abstract: The invention provides a molded coil wherein a sheathing surrounding a coil has no joints.

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.

Abstract: The secondary coil 17 and central iron core 18 are housed in the case, and the primary winding is wound around the surface of the case, and the primary bobbin 14 is abolished.

Abstract: An ignition coil having a core with a first leg and a second leg, a first primary winding arranged over the first leg, a second primary winding arranged over the second leg, a first secondary winding arranged over the first primary winding, a second secondary winding arranged over the second primary winding, and a spark plug terminal electrically connected to one end of the second secondary winding. The first primary winding is connected in series to the second primary winding. The first secondary winding is connected in series to the second secondary winding. The core is of a laminated steel construction. The first and second secondary windings are progressively wound in multiple layers over respective bobbins.

Abstract: An ignition system for an internal combustion engine is designed so that it can be inexpensively produced in a manner advantageous from a standpoint of production engineering. The ignition system includes a shaft in a cylinder head of an internal combustion engine and a coil rod, which can be inserted over a portion of its longitudinal extension into the shaft. The coil rod forms an open magnetic circuit which is controlled by a tubular, longitudinally slit return plate. This return plate is set apart from the coil rod, in the shaft of the cylinder head. The ignition system is intended to be used in the automobile industry.

Abstract: The electronic surface mount package according to the present invention includes a one piece construction package having end walls, a side wall and an open bottom; a plurality of toroid transformers carried within the package by a soft silicone material wherein the toroid transformers each have wires wrapped thereon; a plurality of terminal pins molded within and extending from the bottom of the package wherein each of the pins extend through a bottom portion of the side wall and have a notched post upon which the wires from said transformers are wrapped and soldered thereon, respectively; and wherein the end walls have a first height H1 to form a standoff or safe guard between the foot seating plane of the package and the terminal pins; and wherein the outer portion of the side wall extends between the end walls such that the side wall has a second height H2 which is less than said first height H1.

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: Disclosed herein is a method of fabricating a high frequency thin film coil element having a main coil body composed of a rod shaped ceramic substrate, a thin metallic film layer covering the ceramic substrate, a conductor layer covering the thin metallic film layer, and a plurality of notches which being cut from the conductor layer down to the substrate thereon, and conductor terminals provided at two sides of the main coil body. A protecting layer covering the main body and an anti-oxidation layer, being cut in the similar way as the conductor layer, are sandwiched between the conductor and protecting layers of the main coil body.

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. A reinforcement beam is located laterally across the bottom of the package to provide mechanical strength for the case.

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. A reinforcement beam is located laterally across the bottom of the package to provide mechanical strength for the case.

Abstract: In a first embodiment, an ignition coil includes a disk-shaped primary coil section having a primary coil winding wound thereon and a disk-shaped secondary coil section having a secondary coil winding wound thereon, the primary coil section and secondary coil section facing each other. A core of each winding is aligned with each other to form a coil member. The coil member has a thickness parallel to the thickness direction of the primary and secondary coil sections of from about 10 mm to about 25 mm. The coil member has radial core sections installed on its lower and upper surfaces and is accommodated inside a case member and fixed to the case member by insulation resin injected into the case member. In a second embodiment, a coil winding is wound between upper and lower flange portions of a primary coil winding seat. The axial width of the coil winding is substantially equal to the interval between the pair of flanges.

Abstract: An ignition coil for an internal combustion engine includes a core-coil assembly that includes an endless outer ring core, a straight core intersecting the interior of the outer ring core to form a closed magnetic circuit in cooperation with the outer ring core, and a primary coil and a secondary coil concentrically fitted within the outer ring core and supported by the straight core piercing through the primary coil; and an insulation casing that has a bottom at which a high-voltage terminal connected electrically to an ignition plug is retained, supports and accommodates the core-coil assembly therein so that the core-coil assembly is orthogonal to the axis of the plug hole of the engine, and contains a solid layer of insulating resin cast-molded for fixing the core-coil assembly thereto. The secondary coil is ball-shaped and has coil turns that are largest in number at the equator of the ball and gradually decrease toward the opposite poles of the ball.

Abstract: An ignition device for an internal combustion engine occupies a small amount of space and is suited for efficient manufacturing. For this purpose, the ignition device has an ignition coil which is designed as a bar ignition coil having a coil former arranged concentrically to a longitudinal axis of the ignition coil, an insulation carrier being coaxially attached to the coil former. The coil former is provided with a winding set, the winding wire of which is continued to the insulation carrier. At this point, an interference suppression element in the form of an inductor is implemented in a continued winding. The ignition device is preferably utilized in motor vehicles.

Abstract: Heat emitting electrical components are encased in a refrigerated package within a housing which may be under vacuum. Power for the components is supplied through a transformer within the vacuum housing, the secondary of which is in thermal contact with the package and has heat transmitting electrical connections to the components. To reduce conduction or convection of heat from the primary of the transformer to the refrigerated package, a small gap of about 1 mil is provided. For pot core transformers the core may be split, with the gap between the split portions. For toroidal transformers, the secondary is spaced from the primary as well as from the core by such gap.

Abstract: An inductor includes a coiled metal wire, an insulating molded member in which the coiled metal wire is embedded, and metal caps fitted on both ends of the insulating molded member. The metal caps are welded to both ends of the coiled metal wire. Between the metal caps and the end surfaces of the insulating molded member, spaces are defined respectively. The insulating molded member is made of, for example, resin or rubber.

Abstract: The iron core (2) and the windings (3, 4) of a transformer (1) are held together by a coil former (21) which is arranged in an injection mould in such a way that it comes into contact with said mould only with small parts at its surface, whereas the transformer (1) is a distance away from its walls. A plastic shell (22) is then moulded on to complete a small and light integral casing (7) enclosing the transformer all round and in an abutting manner. Joints between the coil former (21) and the shell (22) are essentially at the bottom of indentations which separate cooling fins (20).

Abstract: A data carrier has a chip with chip contacts, a transmission coil for contactless communication with a write/read station, a metal lead frame with a chip carrying part and contact forming parts, and a chip cover made of electrically insulating material. The transmission coil has coil contacts. The chip cover has a first cover part covering the chip at one side of the metal lead frame and a second cover part covering the other side of the metal lead frame. The second cover part has electrically conducting passages electrically connecting the coil contacts to the contact forming parts that are otherwise connected to the chip contacts. The chip carrying part and the first and second contact forming parts are electrically insulated with respect to each other and are arranged in a substantially coplanar relationship to each other.

Abstract: A method of manufacturing an inductive element for SMD applications comprises the following steps: a) providing a number of predominantly parallel electroconductive wires in the mould of an injection-moulding device, b) circumferentially providing a part of the wires with a synthetic resin by injection moulding, in such a manner that the ends of the wires remain free, c) providing an envelope of a soft-magnetic material around the circumferentially injection moulded part of the wires, and d) reshaping the ends of the wires. The parts of the wires to be circumferentially injection moulded are fixed inside the mould during the injection moulding process. The element generates optimally homogeneous magnetic fields. Also the risk of electric short-circuits is small.