Systems and methods for forming a magnetically-enabled part via additive manufacturing. The method includes depositing a layer of additive manufacturing material on a build plate, melting or sintering the layer of additive manufacturing material, depositing additional layers of additive manufacturing material on previous layers of additive manufacturing material, the additive manufacturing material of at least some of the additional layers being magnetically permeable, and melting or sintering the additional layers of additive manufacturing material such that the magnetically-enabled part has a transition region including at least some of the magnetically permeable additive manufacturing material.

A power control module and a method to create the power control module is provided. The power control module includes a plurality of transformers, wherein each transformer of the plurality of transformers includes a stack of ferrite cores comprising a plurality of ferrite cores and a continuous winding. The continuous winding has a plurality of turns through each ferrite core of the plurality of ferrite cores. The plurality of ferrite cores are oriented such that the plurality of ferrite cores are stacked together with legs of the plurality of ferrite cores oriented in opposite directions, and wherein the continuous winding comprises a folded section that extends between the plurality of ferrite cores of the stack of ferrite.

Electromagnetic inductor components include a magnetic core and a conductor assembled with the core and defining a winding completing a number of turns. The conductor is fabricated from a composite material including carbon nanotubes having an improved conductivity. The conductor has a cross section defined by an effective diameter. The conductor is fabricated to have performance parameters that are selected in view of a function of a ratio of conductivity and/or a function of a ratio of effective diameter of the composite conductor material relative to a reference conductor material as conventionally used in an inductor fabrication.

A method for producing one or more concave cut-outs on a main body, which is in particular substantially cylindrical, more particularly one or more grooves on a magnetic armature, a push rod, or a magnetic keeper plate, includes the following steps: providing a main body, which is in particular substantially cylindrical and has a first axis of rotation, rotating the cylindrical main body around the first axis of rotation in a first rotational direction by means of a lathe, and rotating a striking tool, which is provided with a number of fly cutters, around a second axis of rotation, which extends in parallel and offset in relation to the first axis of rotation in a second rotational direction, which is opposite to the first rotational direction, in such a way that the fly cutter engages in a material-removing manner in the main body to produce the cut-out.

A magnetic assembly includes a bobbin and first and second cores. Each core has a main body. At least one of the cores has first and second outer legs and a center leg extending from the main body. The bobbin includes a first channel on a first end flange and a second channel on a second end flange. Each channel includes a plurality of crushable ribs that extend into the channel. The first and second cores are inserted into the respective first and second channels to engage and crush the crushable ribs. The crushed ribs frictionally engage the main bodies of the two cores to retain the two cores in a fixed relationship with the bobbin without requiring tape or glue. In one embodiment, both cores are E-cores. In another embodiment, one core is an extended E-core and the other core is an I-core.

An electric machine stator includes a soft magnetic yoke having a cylindrical yoke body extending along a central axis, with an outer surface and an inner periphery defining a central opening about the central axis, and a plurality of soft magnetic stator teeth. Each stator tooth defines a first set of air pockets, and a second set of air pockets. An electric machine rotor and permanent magnet material with air pockets are also provided.

An inductor component includes an element body, a coil in the element body, and a non-magnetic insulation layer covering at least part of the coil. The element body includes first and second magnetic layers laminated in order in a first direction. The coil includes a small-turn inductor wiring of 0.5 or less turns extending along a plane orthogonal to the first direction between the first and second magnetic layers. In a first cross-section orthogonal to an extending direction of the small-turn inductor wiring, the small-turn inductor wiring has a top surface facing in the first direction, a bottom surface facing in a second direction opposite from the first direction, a first side surface facing in a third direction orthogonal to the first direction, and a second side surface facing in a fourth direction opposite from the third direction.

The invention relates to a circuit carrier (100), in particular a circuit board, for an electronic circuit, having an electric coil (10) and a core (14), which is designed to form a magnetic field (36) of the coil (10), and the coil (10) has windings (12) situated in layers on top of one another, the coil (12) being integrated into the circuit carrier (100), and the core (14) being situated outside a winding window (18) of the coil (10).

According to some implementations, an apparatus for transmitting charging power wirelessly to a load is provided. The apparatus comprises at least one ferrite structure comprising a first ferrite portion, a second ferrite portion comprising at least a first ferrite leg, a second ferrite leg, and a third ferrite leg, each physically separated from the first ferrite portion by a first distance, and a third ferrite portion positioned between the second ferrite leg and the first ferrite portion and physically contacting the second ferrite leg. The at least one ferrite structure further comprises a coil wound around the second ferrite leg and configured to generate an alternating current under influence of an alternating magnetic field.

A method of producing layered cores for magnetic circuit components such as inductors and transformers suitable for use in the microelectronics industry. A series of pillars are created on a carrier Layers of the magnetic core are plated onto the exposed surface of the pillars. After the desired number of core layers are plated, the plated layers are ground down to expose the pillars, leaving a series of magnetic cores between the pillars. The pillars can then be removed, leaving a series of magnetic cores. The pillars are created by either building up pillars, such as copper pillars, or by slitting plastic mediums, such as dry film or epoxy plastic, the roughness of the magnetic cores produced depends on the method of forming the pillars.