Disclosed are a transfer-molded inductor and a manufacturing method thereof. The inductor comprises a magnet formed by transfer molding with a soft magnetic colloid; and a prefabricated coil assembly comprising an air-core coil and electrode sheets connected at two ends of the air-core coil. The method comprises steps of: connecting a prefabricated air-core coil and an electrode sheet by welding to form a coil assembly, and placing the coil assembly in a cavity of a mold; performing transfer molding with a soft magnetic colloid in a gelatinous state so that the coil is entirely buried in the colloid while the electrode sheets at two ends of the air-core coil are at least partially exposed outside the colloid to serve as terminal electrodes; and performing demolding after the colloid is cured to form a magnet, and finishing the terminal electrodes to obtain the inductor.

An electrical power converter with segmented windings is provided. Comprises a transformer or autotransformer including a magnetic core (3) and at least a primary winding (51) and at least a secondary winding (52) arranged around the magnetic core (3). The primary winding and/or the secondary winding have at least one full turn that includes at least one power switch (10) and at least one capacitor (12) connected in series and arranged respectively opposite each other and facing opposite sides of the magnetic core, defining a cell (4) that is divided in four segments, a first segment (23) including said at least one switch, a second opposite segment (24) including said at least one capacitor, and two other connecting segments (21, 22) providing electrical connection between the first segment and the second segment, and each of said two other connecting segments having opposite electrical polarity.

A magnetic component structure with thermal conductive filler, including two magnetic cores combining together to form an inner accommodating space and at least one core opening, two plate portions connect each other through an inner leg structure and two outer leg structures, a bobbin sleeving on the inner leg structure, a coil winding on the bobbin, a bobbin housing surrounding the bobbin and the coil winding and form winding opening facing the at least one core opening, gaps are formed between the encasing structure constituted by the bobbin housing and the bobbin sleeving and the magnetic cores, a thermal conductive filler formed between the bobbin and the bobbin housing and encapsulating at least parts of the coil winding, and a cooling surface contacts the magnetic cores and the thermal conductive filler, the thermal conductive filler extends outwardly to contact the cooling surface through the opening and the winding opening.

A magnetic component structure with thermal conductive filler, including two magnetic cores combining together to form an inner accommodating space and at least one core opening, two plate portions connect each other through an inner leg structure and two outer leg structures, a bobbin sleeving on the inner leg structure, a coil winding on the bobbin, a bobbin housing surrounding the bobbin and the coil winding and form winding opening facing the at least one core opening, gaps are formed between the encasing structure constituted by the bobbin housing and the bobbin sleeving and the magnetic cores, a thermal conductive filler formed between the bobbin and the bobbin housing and encapsulating at least parts of the coil winding, and a cooling surface contacts the magnetic cores and the thermal conductive filler, the thermal conductive filler extends outwardly to contact the cooling surface through the opening and the winding opening.

The invention comprises an apparatus, comprising an inductor, the inductor comprising: an inductor core; a first winding section comprising a first cast shape and a second winding section comprising the first cast shape, the first winding section mechanically joined to the second winding section to form a winding, the winding forming a wound shape about the inductor core. Optionally and preferably, a third winding section, comprising a second cast shape, mechanically joins the first winding section to the second winding section and a mechanical connector and/or an aluminum weld join the first winding section to the third winding section.

A magnetic device includes a magnetic core assembly and a winding assembly. The magnetic core assembly includes a first outer magnetic leg, a second outer magnetic leg, a first inner magnetic leg group and a second inner magnetic leg group. A first channel is formed between the first inner magnetic leg group and the first outer magnetic leg. A second channel is formed between the second inner magnetic leg group and the first inner magnetic leg group. A third channel is formed between the second inner magnetic leg group and the second outer magnetic leg. The winding assembly includes four coupled windings. The first terminals of the four coupled windings are located near a first lateral side of the magnetic core assembly. The second terminals of the four coupled windings are located near a second lateral side of the magnetic core assembly.

A magnetic component is provided. The magnetic component comprises a primary coil group, a secondary coil group, and a magnetic core. A first primary coil and a second primary coil of the primary coil group are winding around a first winding column and a second winding column of the magnetic core, respectively. The number of turns of the first primary coil is different from the number of turns of the second primary coil. A first secondary coil and a second secondary coil of the secondary coil group are winding around the first winding column and the second winding column, respectively. The number of turns of the first secondary coil is different from the turns of the second secondary coil.

A structure for forming inductor windings includes a first portion and a second portion of a clamshell casing. The first portion includes a first set of electrically conductive segments, a first inner carrier, and a first outer carrier. The second portion includes a second set of electrically conductive segments, a second inner carrier, and a second outer carrier. An inductor core is mountable between the first inner carrier and the first outer carrier within the first portion. A control assembly aligns and joins the first portion to the second portion of the clamshell casing such that the first set of electrically conductive segments arranged in the first pattern that correspond to first half-turns of the inductor windings, are attached to the second set of electrically conductive segments arranged in the second pattern that correspond to second half-turns of the inductor windings, to form continuous turns around the inductor core.

A three-phase AC reactor according to an embodiment of the present invention includes three-phase coils that are not arranged in parallel, an input and output terminal block having an input and output unit having a parallel arrangement, and an external connection position change unit disposed between a coil end of each of the three-phase coils and the input and output terminal block to connect the coil end to the input and output terminal block.

A three-phase AC reactor according to an embodiment of the present invention includes three-phase coils that are not arranged in parallel, an input and output terminal block having an input and output unit having a parallel arrangement, and an external connection position change unit disposed between a coil end of each of the three-phase coils and the input and output terminal block to connect the coil end to the input and output terminal block.