The invention comprises a method for manufacturing an inductor, comprising the steps of: casting a first cast winding section; casting a second cast winding section; and mechanically coupling the first cast winding section to the second cast winding section to form a section of a winding about a core of the inductor. Optionally, a first end of a connector section is welded to the first cast winding section and a second end of the connector section is welded to the second cast winding section, where the first and second cast winding sections have a common cast shape.

A heat exchanger package for a dry-type transformer is provided. The heat exchanger package includes a package housing including an air inlet and an air outlet and adapted to fix to the dry-type transformer; and a first heat exchanger located in the package housing and between the air inlet and the air outlet, the first heat exchanger arranged at a first angle of inclination with respect to a first inner surface of the package housing.

A power module of a medium-high-voltage isolated converter is disclosed. The power module includes a first circuit, a second circuit, a transformer and a shielding structure. A potential of the first circuit is greater than a potential of the second circuit. The transformer includes a first leading wire electrically connected to the first circuit, and a second leading wire electrically connected to the second circuit. The shielding structure is disposed between the transformer and the second circuit. The second leading wire is electrically connected between the transformer and the second circuit through the shielding structure, and the shielding structure is maintained at a constant potential.

The invention comprises a method, including the steps of: providing an inductor core and longitudinally joining a first electrical turn section to a second electrical turn section to form at least part of an electrical turn of a winding about the inductor core and optionally including at least one of the steps of: (1) additive manufacturing, casting, stamping from metal stock, cutting material, and/or bending metal to form the first electrical turn section and/or (2) welding and/or mechanically joining the first electrical turn section to the second electrical turn section.

The invention comprises a method for forming an inductor, comprising the steps of: providing an inductor core and fastening at least ten sections of a winding together to form a winding, the winding comprising a formed wound shape about the inductor core. Optionally and preferably the step of fastening repeats steps of joining a member of a first set of winding parts to an element of a second set of winding parts, where the two sets of winding parts have different cast or formed shapes.

A stationary induction charging station for a vehicle is disclosed. The stationary induction charging station includes an induction charging device, an energy transfer module for contact-free energy transfer, and an electronic unit. According to an example, the energy transfer module and the electronic unit are spatially combined.

A low pass filter is disclosed. In an embodiment a low-pass filter includes a current-compensated choke, a reference potential and a capacitor connected in parallel with the current-compensated choke and to the reference potential, wherein a core of the current-compensated choke is configured to have a magnetic circuit, and wherein the core has an air gap.

The invention comprises a method of: providing an inductor core, placing a winding guide within an inch of the inductor core, positioning a first turn element with the winding guide, positioning a second turn element with the winding guide, and mechanically coupling the first turn element to the second turn element to form at least a part of a winding, the winding forming a wrapped shape about the inductor core. Optionally and preferably, turn elements are subsequently joined, mechanically coupled, and/or welded together to form sections of the winding.

Systems, methods and apparatus for wireless charging are disclosed. A wireless charging device has a plurality of planar power transmitting coils, a driver circuit and at least one substrate having channels formed therein. The channels can receive a flow of air at a port of entry and conduct the flow of air through the substrate to a port of exit. The planar power transmitting coils may be supported by at least one substrate. Each planar power transmitting coil may be formed as a spiral winding surrounding a power transfer area. The driver circuit may be configured to provide a charging current to one or more of the planar power transmitting coils when a chargeable device is placed on or near the wireless charging device. The one or more channels may be configured to conduct the flow of air past or through the planar power transmitting coils and the driver circuit.

A thermal management includes an inductor, a housing in thermal communication with the inductor, the housing defining a wall, and a conductor. The conductor has a greater heat transfer rate than the wall and is positioned within a groove and/or an aperture formed in the wall. The conductor is configured to transfer heat through the wall more efficiently than if the conductor were not present. A method of manufacturing a thermal management system includes forming a housing by additive manufacturing. The housing defines a wall having at least one of a groove and an aperture defined therein. The method includes positioning a conductor in at least one of the groove and the aperture. The conductor has a greater heat transfer rate than the wall. The method includes positioning an inductor into thermal communication with the housing.