A method of fabricating an electromagnet includes obtaining a first flexible PCB that includes one or more first conductive coiled traces and obtaining a second flexible PCB that includes one or more second conductive coiled traces. The first flexible PCB is bent into a shape having at least one curve or corner. With the first flexible PCB having been bent into the shape, the second flexible PCB is then bent into the shape: the second flexible PCB is positioned adjacent to the first flexible PCB to conform with the first flexible PCB. The second flexible PCB may substantially surround the first flexible PCB. An electrostatic deflector may be disposed concentrically with the first and second flexible PCBs.

The present invention relates to an inductor device, a method of manufacturing same and antenna. The proposed inductor device comprising a magnetic core (1), an electrically insulating support (10) with a cavity (11) arranged around said magnetic core (1), and three windings (DX, DY, DZ) of conductive wire arranged orthogonal to one another, wherein said electrically insulating support (10) is made of a single part and completely houses the magnetic core (1) which is accessible through an opening, the three windings (DX, DY, DZ) being supported on winding supporting faces (12X, 12Y and 12Z) of the electrically insulating support, confined between winding limiting edges (22) defined by lower corner protuberances (20) and centered with respect to the three orthogonal axes (X, Y, Z) such that said electrically insulating support (10) assures symmetry and orthogonality of said electromagnetic field vectors generated by the mentioned inductor device.

The present invention relates to an inductor device, a method of manufacturing same and antenna. The proposed inductor device comprising a magnetic core (1), an electrically insulating support (10) with a cavity (11) arranged around said magnetic core (1), and three windings (DX, DY, DZ) of conductive wire arranged orthogonal to one another, wherein said electrically insulating support (10) is made of a single part and completely houses the magnetic core (1) which is accessible through an opening, the three windings (DX, DY, DZ) being supported on winding supporting faces (12X, 12Y and 12Z) of the electrically insulating support, confined between winding limiting edges (22) defined by lower corner protuberances (20) and centered with respect to the three orthogonal axes (X, Y, Z) such that said electrically insulating support (10) assures symmetry and orthogonality of said electromagnetic field vectors generated by the mentioned inductor device.

Structures and methods for reducing physical space of two or three inductors while maintaining low magnetic coupling between the inductors are presented. According to one aspect, the inductors share their volume spaces and have (substantially) orthogonal far field magnetic vectors. According to another aspect, the inductors are fabricated on planar layers of a stacked structure that includes conductive and non-conductive layers. According to an additional aspect, a coil structure of one of the inductors passes through a volume space of another inductor. According to another aspect, coil structures of two of the inductors are interlaced. According to another aspect, relative placement of two coil structures of two inductors is based on a number of windings of one of the two coil structures above and below the other coil structure. According to another aspect, a shape of a coil structure of one inductor follows a near field magnetic vector of another inductor.

Structures and methods for reducing physical space of two or three inductors while maintaining low magnetic coupling between the inductors are presented. According to one aspect, the inductors share their volume spaces and have (substantially) orthogonal far field magnetic vectors. According to another aspect, the inductors are fabricated on planar layers of a stacked structure that includes conductive and non-conductive layers. According to an additional aspect, a coil structure of one of the inductors passes through a volume space of another inductor. According to another aspect, coil structures of two of the inductors are interlaced. According to another aspect, relative placement of two coil structures of two inductors is based on a number of windings of one of the two coil structures above and below the other coil structure. According to another aspect, a shape of a coil structure of one inductor follows a near field magnetic vector of another inductor.

Implementations of a system and method for building electromagnetic coil structures are provided. In some implementations, the system for building electromagnetic coil structures comprises one or more top parts, bottom parts, hub circles, support rings, adapter rings, base circles, and/or dividers.

In some implementations, the method for building electromagnetic coil structures comprises connecting the one or more top parts, bottom parts, hub circles or adapter rings, and support rings to build an electromagnetic coil structure. In some implementations, the method for building electromagnetic coil structures comprises connecting the one or more base circles and dividers to build an electromagnetic coil structure, and in some implementations further comprises connecting the one or more support rings and/or hub circles to build the electromagnetic coil structure.

A coil block manufacturing method of winding a wire around a coil core in which a core portion is provided between a first attachment portion and a second attachment portion, includes: a first step of fixing one end of the wire; a second step of, in a state of holding the first attachment portion of the coil core by a first chuck to expose the whole core portion, winding the wire around an end of the core portion; and a third step of, in a state of holding the second attachment portion of the coil core by a second chuck to expose the whole core portion, winding the wire around the whole core portion, to form a coil portion.

A coil block manufacturing method of winding a wire around a coil core in which a core portion is provided between a first attachment portion and a second attachment portion, includes: a first step of fixing one end of the wire; a second step of, in a state of holding the first attachment portion of the coil core by a first chuck to expose the whole core portion, winding the wire around an end of the core portion; and a third step of, in a state of holding the second attachment portion of the coil core by a second chuck to expose the whole core portion, winding the wire around the whole core portion, to form a coil portion.

A coil forming apparatus includes: a coil winding jig that winds the belt-shaped coil, the coil winding jig including a plurality of comb-shaped grooves on an outer periphery thereof; a coil conveying mechanism that pivotally conveys the belt-shaped coil along at least a portion of the outer periphery of the coil winding jig; and guide members guide the belt-shaped coil in an arc shape while being in contact with the side ends. The guide members guide the belt-shaped coil so as to be in an arc shape having a diameter smaller than an outer diameter of the coil winding jig in a second half portion of the belt-shaped coil upon pivot conveying, and allow the plurality of straight portions to be inserted into a respective one of the plurality of comb-shaped grooves of the coil winding jig.

The present invention was contrived through attention being focused on the following in a prior-art distributed-winding coil: a solenoid configuration in which winding wires are to be wound is preserved when initially formed, but this configuration tends to be loosened during subsequent steps, and the initial winding sequence of the winding wires, or the position of the winding wires relative to each other, tends to be disrupted, and accordingly must be prevented, when a certain force is applied and the necessary bending or deformation is induced in coils with distributed winding in which the solenoid configuration is preserved, or when the coils are ultimately inserted into slots. Therefore, as a solution, the present invention provides a holding tool 30 provided with: at least two substrates 32 linked at one end so as to be able to open and close; an outlet 31 formed at the other end of the substrates 32; and a holding space 32a capable of opening on the outlet 31 side, and holding the first accommodation portion 11a or the second accommodation portion 11b of a coil 10 while maintaining the alignment state of the winding wires 10A that constitute part of the first accommodation portion 11a and the second accommodation portion 11b when the substrates 32 are closed; the holding tool 30 being capable of forming a twist portion at a first coil end and a second coil end and reducing the size of the coil ends of the coils while maintaining the alignability of the winding wires that constitute part of the first and second accommodation portions of the coil 10.