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.

Disclosed is a nonlinear inductor, a manufacturing method thereof, and a nonlinear inductor row. The nonlinear inductor includes two magnetic core assemblies, a conductor and a magnetic plastic encapsulation layer; the magnetic core assemblies include magnetic cores; each magnetic core includes a flange and a central column arranged on the flange; two central columns of the two magnetic core assemblies are opposite to each other; a non-uniform air gap exists between the two central columns and/or the magnetic core assemblies are made of different materials; the conductor is arranged on the two central columns; the two magnetic core assemblies and the conductor are located in the magnetic plastic encapsulation layer; electrode parts of the conductor are exposed outside the magnetic plastic encapsulation layer; and the magnetic core assemblies and the magnetic plastic encapsulation layer are made of different materials; thereby the nonlinear inductor has stepped saturation characteristics.

A coupled inductor having a body, wherein a first electrode and a second electrode are connected to a first coil, and a third electrode and a fourth electrode are connected to a second coil, wherein a first horizontal line segment passing through the first electrode and the second electrode and a second horizontal line segment passing through the third electrode and the fourth electrode crosses each other at a location inside the periphery of a bottom surface of the body.

Electro-magnetic devices are provided, having conductive elements and leads of multiple thicknesses. Templates are provided for making electro-magnetic devices, formed by an extrusion process, a skiving process, a swaging process, 3D printing, or a machining process. The multi-thickness electro-magnetic devices may comprise a conductive element having an increased thickness area, and one or more leads having at least one decreased thickness area, having a thickness less than the increased thickness area. An electro-magnetic device may be provided comprising a conductive element having an increased thickness encased in a body formed from a core material, and leads or lead portions connected to the conductive element having a decreased thickness.

A highly reliable coil device is provided. An inductor 1 includes a coil 2 formed of a flat wire, a first terminal 4a including a first wire connecting portion 42a formed with a first accommodation recessed portion 421a in which a first lead-out portion 3a of the coil 2 is accommodated, and a second terminal 4b including a second wire connecting portion 42b formed with a second accommodation recessed portion 421b in which a second lead-out portion 3b of the coil 2 is accommodated, in which the first accommodation recessed portion 421a and the second accommodation recessed portion 421b are displaced from each other along a winding axis direction of the coil 2.

A highly reliable coil device is provided. An inductor 1 includes: a core 8; a coil 2 embedded inside the core 8; and terminals 4a and 4b provided with wire connecting portions 42a and 42b, to which lead-out portions 3a and 3b of the coil 2 are connected, the wire connecting portions 42a and 42b being disposed inside the core 8, in which the terminals 4a and 4b are disposed inside the core 8, and the terminals 4a and 4b include base portions 41a and 41b on which a second end portion 2b of the coil 2 in a winding axis direction is provided.

A method for producing a coil for a transformer, in particular for a medium frequency transformer for a resonant DC/DC converter or a dual active bridge DC/DC converter, is disclosed which: providing a plurality of M>1 conductive foil strips, each having a first ending and a second ending; stacking the plurality of conductive foil strips to obtain a foil strip stack having a first ending and a second ending, wherein an electrically insulating layer is provided between any two adjacent foil strips; electrically interconnecting the first endings of all conductive foil strips to a first terminal; for each of the conductive foil strips providing a connector at the second ending of the foil strip; and coiling up the foil strip stack from the first end.

A magnetic element. In some embodiments, the magnetic element includes a first electrically conductive coil, having a first annular surface and a second annular surface; a second electrically conductive coil, having a first annular surface and a second annular surface; and a spacer between the first electrically conductive coil and the second electrically conductive coil; a fluid inlet; and a fluid outlet. The spacer may have a first face, the first face being separated from the first annular surface of the first electrically conductive coil by a first gap; and a fluid path may extend from the fluid inlet to the fluid outlet through the first gap.

A coil device includes a pair of first core and second core, a third core, and a pair of first coil and second coil. The third core is disposed next to the first core or the second core. The pair of first coil and second coil is each disposed between any two of the first core, the second core, and the third core next to each other. Plate surfaces of the first coil and the second coil are opposed to each other. Each of the first coil and the second coil is partly exposed in a lateral direction of the first core, the second core, or the third core.

A coil device includes a core and a plurality of coils arranged in the core. A distance of a second gap formed by portions of the core located inside at least one of the coils is larger than that of a first gap formed by other portions of the core located between the coils next to each other.