A magnetic component comprising one or more wound magnetic cores in a housing and held stationary in the housing by a solid potting mass, characterized in that the housing has one open top face and at least one open side, the potting mass having a top boundary parallel to the open top face and at least one side boundary adjacent to or coincident with the at least one open side. The inventive component can be fabricated by closing the open sides with barriers to create a cavity with an open top and fluid-tight bottom that can be filled with potting and hold the wound core cores.

A laminated coil includes planar coils and a first insulating member. The planar coils are arranged in a first direction intersecting a first surface. The first insulating member is in a film form and arranged between a pair of planar coils adjacent to each other in the first direction. At least one of the planar coils is wound to have a plurality of turns spaced apart from each other in a second direction along the first surface. A second insulating member is arranged between the turns adjacent to each other in the second direction of at least one of the planar coils.

In a method of manufacturing an embedded magnetic component, a cavity is formed in an insulating substrate. One or more drops of adhesive are applied to the cavity and a magnetic core is inserted in the cavity. The cavity and the magnetic core are then covered with a first insulating layer. Through holes are formed through the first insulating layer and the insulating substrate, and plated up to form conductive vias. Metallic traces are added to exterior surfaces of the first insulating layer and the insulating substrate to form upper and lower winding layers. The metallic traces and the conductive vias form the windings for an embedded magnetic component, such as a transformer or an inductor.

Sheet metal construction is described for achieving high strength at low weight for a power reactor and for an impedance injection module incorporating the power reactor. Clamping plates are used to retain the core and the windings of the reactor. Integrated features of a specialized frame of the impedance injection module include flanges for structural rigidity, a convenient yoke plate for lifting by crane, feet for mounting insulators, and sufficient strength to maintain mechanical integrity during normal operation and also during fault conditions. The specialized frame provides a light weight assembly suitable for mounting on power transmission lines as well as on ground assemblies. The specialized frame can reduce the cost of the total enclosure to around 25% of the cost and 50% of the weight of an equivalent conventional enclosure. An insulation topology is also described.

A base includes a support plate, an inner wall provided on the support plate, an outer wall arranged apart from the inner wall in a first direction parallel to an upper surface of the support plate, and an insulating cover protruding from the outer wall in the first direction, wherein the outer wall and the inner wall extend in a second direction crossing the first direction.

A circuit assembly that includes an inductor including a core; a fixation member to which the inductor is fixed; a base that is attached to the core, wherein: the fixation member is made of a first material having a coefficient of thermal expansion larger than a coefficient of thermal expansion of the core, and the base is made of a second material having a coefficient of thermal expansion larger than the coefficient of thermal expansion of the core and smaller than the coefficient of thermal expansion of the fixation member; and an adhesive layer that is disposed between the base and the fixation member, and that bonds the base and the fixation member together.

A reactor includes a coil; a magnetic core with an inner core portion arranged inside the coil; and an inwardly interposed member insulating the coil from the inner core portion. The inwardly interposed member has a thin portion defined by a recess of an inner-circumferential surface, and a thick portion that is thicker than the thin portion. The inner core portion has, on an outer circumferential surface facing the inwardly interposed member, a core-side projection portion has a shape conforming to the inner-circumferential surface shape of the thin portion. The thin portion has a thickness of 0.2 mm to 1.0 mm inclusive, and the thick portion has a thickness of 1.1 mm to 2.5 mm inclusive. The inner core portion and the inwardly interposed member are in intimate contact with each other, and the inwardly interposed member and the wound portion are in intimate contact with each other.

A coil includes unit coils wound around a central axis and adjacent to each other with a space therebetween in a central axis direction. A reactor includes a pair of support frames and one or more spacers, the support frames facing each other in the central axis direction across the coil. The spacers are disposed between adjacent unit coils or between the support frame and the coil. At least one of the spacers is a variable spacer that includes a first member and a second member, the first member having one end face which has a recess, and the second member including a fitting portion to be fitted into the recess of the first member in the central axis direction. The linear expansion coefficient of the second member is less than the linear expansion coefficient of the first member.

A bus bar arrangement including two or more bus bars arranged for conducting currents, wherein the two or more busbars are arranged parallel and at a distance from each other, the arrangement including a magnetic structure which is arranged between two bus bars which are next to each other.

A coil apparatus includes a coil unit including a coil, a base core that is a first core component, and a core module that is a second core component. The first core component includes a center leg that is a leg around which the coil is wound. The second core component includes a plurality of core segments arranged in a row with gaps between them. The second core component is connected to the leg to form a magnetic path together with the first core component.