The present invention provides a method of manufacturing magnets, including magnets comprising coil windings which may be multiple meters in length. In an embodiment, the support structure comprises a cylinder in which machined grooves are formed to define the magnet conductor path. The segments may consist of a composite material or a metal in the shape of a cylinder, but which need not be manufactured from a single piece of material. Rather, the support structure may be formed in multiple connectable segments which, when connected together, form a completed wiring support structure. Each segment may be of sufficient length to support multiple individual coil turns in a helical configuration. When the segments are connected the helical configuration continues without interruption from connectable segment to connectable segment. The segmented wiring support structure of the invention may be applied to linear or curved magnet geometries.

The present invention provides a method of manufacturing magnets, including magnets comprising coil windings which may be multiple meters in length. In an embodiment, the support structure comprises a cylinder in which machined grooves are formed to define the magnet conductor path. The segments may consist of a composite material or a metal in the shape of a cylinder, but which need not be manufactured from a single piece of material. Rather, the support structure may be formed in multiple connectable segments which, when connected together, form a completed wiring support structure. Each segment may be of sufficient length to support multiple individual coil turns in a helical configuration. When the segments are connected the helical configuration continues without interruption from connectable segment to connectable segment. The segmented wiring support structure of the invention may be applied to linear or curved magnet geometries.

A solenoid coil includes a coil winding that generates an electromagnetic force when a current is supplied to the coil winding. The solenoid coil also includes an electrically insulative bobbin made of an insulating material having a melting point. The bobbin includes a spool for supporting the coil winding. The spool includes a first end and a second end opposite the first end. The coil winding is positioned between the first end and the second end. The bobbin also includes a flange connected to one of the first end and the second end. A continuous ridge extends from the flange between an outer edge and studs to form a moisture barrier. The solenoid coil further includes an overmold enclosing at least a portion of the bobbin and the coil winding. The overmold bonds to the continuous ridge when the solenoid coil is heated to a temperature above the melting point.

A solenoid coil includes a coil winding that generates an electromagnetic force when a current is supplied to the coil winding. The solenoid coil also includes an electrically insulative bobbin made of an insulating material having a melting point. The bobbin includes a spool for supporting the coil winding. The spool includes a first end and a second end opposite the first end. The coil winding is positioned between the first end and the second end. The bobbin also includes a flange connected to one of the first end and the second end. A continuous ridge extends from the flange between an outer edge and studs to form a moisture barrier. The solenoid coil further includes an overmold enclosing at least a portion of the bobbin and the coil winding. The overmold bonds to the continuous ridge when the solenoid coil is heated to a temperature above the melting point.

A coil form with a low inter-winding capacitance is disclosed including a bobbin formed from an electrically insulating material and including a tube section shaped wall. A coil is mechanically supported by the bobbin and includes a first plurality of conductor windings on the outside of the wall and a second plurality of conductor windings on the inside of the wall. Furthermore, a transformer with such a coil form as any of its primary or secondary windings is disclosed.

A coil form with a low inter-winding capacitance is disclosed including a bobbin formed from an electrically insulating material and including a tube section shaped wall. A coil is mechanically supported by the bobbin and includes a first plurality of conductor windings on the outside of the wall and a second plurality of conductor windings on the inside of the wall. Furthermore, a transformer with such a coil form as any of its primary or secondary windings is disclosed.

The invention relates to a method for manufacturing a pole tube, with two magnetic pole tube parts, for an electromagnet, in particular for a magnetic valve of an automatic transmission in an automobile, including the following steps: (a) arranging the pole tube parts on a centering arbor; and (b), connecting, in particular insert molding and/or casting an outer lateral surface of the pole tube parts; wherein the centering arbor has a radially expandable cylinder surface also closed even in the expanded state. Further, the invention relates to, in particular with the method obtainable, a pole tube, an electromagnet for a magnetic valve, in particular for an automatic transmission in an automobile, having a pole tube according to the invention, and an apparatus for the manufacture of the pole tube.

The invention relates to a method for manufacturing a pole tube, with two magnetic pole tube parts, for an electromagnet, in particular for a magnetic valve of an automatic transmission in an automobile, including the following steps: (a) arranging the pole tube parts on a centering arbor; and (b), connecting, in particular insert molding and/or casting an outer lateral surface of the pole tube parts; wherein the centering arbor has a radially expandable cylinder surface also closed even in the expanded state. Further, the invention relates to, in particular with the method obtainable, a pole tube, an electromagnet for a magnetic valve, in particular for an automatic transmission in an automobile, having a pole tube according to the invention, and an apparatus for the manufacture of the pole tube.

The present disclosure relates to a solenoid of an electromagnetic valve where the number of processes can be reduced and breaking of a conductive wire can be suppressed in a simple structure, and the solenoid of the electromagnetic valve according to the present disclosure comprises a conductive wire; a bobbin having a tubular winding portion where the conductive wire is wound around in a coil shape and a flange portion disposed on both end portions of the winding portion; a terminal portion which is disposed on the flange portion and protrudes in a planar shape in a direction perpendicular to the central axis of the bobbin on a radially outer side than the winding portion relative to the central axis, and in which two terminals are provided on a distal end portion side; and two wall portions which are disposed on both sides of the terminal portion in a width direction, stand upright in a central axis direction and face each other, wherein both end portions of the conductive wire are drawn out from the bobbin to the terminal portion, directed toward a radially outer side from a winding portion side of the two wall portions and electrically connected to the terminals.

A highly reliable winding part is provided which is capable of providing insulation with reliability. A core is attached to a bobbin along a first direction. First terminals and second terminals are disposed along the first direction. A first terminal group and a second terminal group are disposed with the core interposed between the groups. A first insulation portion or a recess along a second direction that is not parallel to the first direction is provided between the first terminals and the second terminals, and a second insulation portion or a core groove along the first direction is provided between the first terminal group and the second terminal group.