A planar coil (10) of the present disclosure includes a base (1) including a first surface (1a), a metal layer (2) located on the first surface (1a) and including a through hole (2a) and a plurality of voids (3), and a first fixing tool (8) inserted through the through hole (2a) and fixing the metal layer (2) to the first surface (1a) side of the base (1).

A resin producing method is a method of producing a resin with which an insulating structure formed on an outer peripheral portion of a conductor is impregnated, the method including: a filler mixing step of mixing a nanofiller at a ratio of 15 wt % or more with an epoxy resin to form a mixture; a shear mixing step of causing the mixture to be subjected to shear mixing; a diluent mixing step of mixing a reactive diluent that reduces a viscosity of the epoxy resin, with the mixture after the shear mixing step; and a curing agent mixing step of mixing an acid anhydride curing agent with the mixture after the diluent mixing step.

To provide an insulated wire that can increase in a partial discharge starting voltage, prevent deterioration of an insulator, and not cause worsening of an occupancy ratio, a coil that uses the insulated wire, a variable-thickness insulating tape used in manufacture of the insulated wire, and a manufacturing method of the same. The above-described problem is solved by an insulated wire (10) for a coil, comprising a conductor (1), and insulating coatings (2, 3) provided on an outer periphery of the conductor (1). The insulated wire (10) is constituted by the thick insulating coating (3) for an area where voltage increases and partial discharge readily occurs, and the thin insulating coating (2) for an area where the voltage does not increase and partial discharge does not readily occur, when the coil is wound. The thick insulating coating (3) and the thin insulating coating (2) are repeatedly provided at desired intervals. The above-described problem is solved by a coil (40) obtained by winding such an insulated wire (10) and configured so that the insulating coating (3) of the insulated wire (10) in an area where partial discharge readily occurs is thick, and the insulating coating (2) of the insulated wire (10) in an area where partial discharge does not readily occur is thin.

To provide an insulated wire that can increase in a partial discharge starting voltage, prevent deterioration of an insulator, and not cause worsening of an occupancy ratio, a coil that uses the insulated wire, a variable-thickness insulating tape used in manufacture of the insulated wire, and a manufacturing method of the same. The above-described problem is solved by an insulated wire (10) for a coil, comprising a conductor (1), and insulating coatings (2, 3) provided on an outer periphery of the conductor (1). The insulated wire (10) is constituted by the thick insulating coating (3) for an area where voltage increases and partial discharge readily occurs, and the thin insulating coating (2) for an area where the voltage does not increase and partial discharge does not readily occur, when the coil is wound. The thick insulating coating (3) and the thin insulating coating (2) are repeatedly provided at desired intervals. The above-described problem is solved by a coil (40) obtained by winding such an insulated wire (10) and configured so that the insulating coating (3) of the insulated wire (10) in an area where partial discharge readily occurs is thick, and the insulating coating (2) of the insulated wire (10) in an area where partial discharge does not readily occur is thin.

A coil module includes a coil conductor including a plurality of coil elements and a plurality of wire electrodes disposed on a circuit board, each of the plurality of coil elements including a pair of leg portions and a bridge portion connecting one end portions of the pair of leg portions together, the plurality of coil elements being disposed to cross a winding axis. A method for manufacturing the coil module includes an assembly forming step of integrating the plurality of coil elements with resin to form a coil element assembly, and a conductor forming step of mounting the coil element assembly on the circuit board to complete the coil conductor wound about the winding axis. In the conductor forming step, the resin is introduced into a die set in which the plurality of coil elements are arranged to form a block, to thus form the coil element assembly.

A coil module includes a coil conductor including a plurality of coil elements and a plurality of wire electrodes disposed on a circuit board, each of the plurality of coil elements including a pair of leg portions and a bridge portion connecting one end portions of the pair of leg portions together, the plurality of coil elements being disposed to cross a winding axis. A method for manufacturing the coil module includes an assembly forming step of integrating the plurality of coil elements with resin to form a coil element assembly, and a conductor forming step of mounting the coil element assembly on the circuit board to complete the coil conductor wound about the winding axis. In the conductor forming step, the resin is introduced into a die set in which the plurality of coil elements are arranged to form a block, to thus form the coil element assembly.

An enhanced safety coil that prevents crack formation and propagation to the coil windings from external sources and prevents exposure to fuel is provided. The enhanced safety coil may be used in a solenoid operated gas admission valve (SOGAV), and includes a plastic encapsulation body having at least one body de-stress feature, a coil wound on the plastic encapsulation body, a sleeve forming an outermost side protective wall configured to accommodate the plastic encapsulation body and coil therewithin, and potting provided between the plastic encapsulation body and the sleeve to seal the coil therein. The body de-stress feature is configured to reduce at least one of a formation or a propagation of a crack through the potting to the coil. The plastic encapsulation body forms retention latches configured to mate with a stator.

Magnet wire included extruded insulation formed from a blend of two or more different polymeric materials is described. A magnet wire may include a conductor and insulation formed around the conductor. The insulation may include at least one layer of extruded insulation formed from a blend of a first polymeric material and a second polymeric material different than the first polymeric material. The first polymeric material may include one of polyetheretherketone, polyaryletherketone, polyetherketoneketone, polyphenylsulfone, polyphenylene sulfide, or polybenzimidazole. The second polymeric material may include one of polyphenylsulfone, polyetherimide, polyethersulfone, polyphenylene sulfide, polycarbonate, or polyester.

A coil includes: a series of turns constituted by a first turn to an n-th turn of a conductive wire having a polygonal cross-section, where n is an integer equal to or larger than 3, and the conductive wire is wound in a spiral shape and is stacked in a direction from downward toward upward; and an insulating member disposed on either an upper surface or a lower surface of an i-th turn, where i is an integer satisfying 1≤i≤n.

Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a thermoset polymeric material and process the thermoset polymeric material to increase its pressure and temperature. An extrusion crosshead assembly in fluid communication with the extruder may receive the thermoset polymeric material and press extrude the thermoset polymeric material as insulation onto a magnet wire. A curing device may then cure the extruded insulation material.