A transformer is described. The transformer includes a transformer core having a core leg having a longitudinal axis, a low voltage winding arranged around the core leg, the low voltage winding extending along a first length in the direction of the longitudinal axis, a high voltage winding arranged around the low voltage winding, the high voltage winding extending along a second length in the direction of the longitudinal axis, wherein the second length is shorter than the first length, and a casting embedding the low voltage winding and the high voltage winding. The casting has a recess. The recess is provided at a radial location of the high voltage winding and the recess extends in the direction of the longitudinal axis.

A method for assembling a magnetic inductor for an electromagnetic pump comprising the following steps: providing a plurality of magnetic laminations having a cross section of an involute of a circle; assembling the plurality of magnetic laminations by fitting same into an inductor core; cutting out at least one housing for an elementary coil; providing and placing an elementary coil inside each housing formed in the cutting step and thereby forming the magnetic inductor. Further, a magnetic inductor formed by implementing such a method and an electromagnetic pump including at least one magnetic inductor.

An electromagnetic coil that can withstand high temperatures and operate efficiently and methods of making the same are provided. In preferred embodiments the electromagnetic coil comprises: a bobbin made entirely of ceramic; a coiled conductor wrapped around the bobbin; a potting resin applied to the coiled conductor during winding wherein, the resin is a siloxane polymer mixed with a metal oxide or a cyanate ester; and an overwind made of glass fiber yarn.

An electromagnetic coil that can withstand high temperatures and operate efficiently and methods of making the same are provided. In preferred embodiments the electromagnetic coil comprises: a bobbin made entirely of ceramic; a coiled conductor wrapped around the bobbin; a potting resin applied to the coiled conductor during winding wherein, the resin is a siloxane polymer mixed with a metal oxide or a cyanate ester; and an overwind made of glass fiber yarn.

As wire is wound around and onto the surface of a former to form a coil, perturbations such as waves are introduced into turns of the coil, each perturbation being formed in a length of the wire less than the full length of a respective turn and projecting along the former surface, the perturbation having an initial shape and size. The coil is taken from the former and fixed in form. A surrounding jacket is radially collapsed onto the wire coil to uniformly press the coil against an internal compressible body in the course of which the overall diameter of the coil is reduced. Resulting stresses in the wire generated during the collapse are relieved by alteration of the perturbations from their initial shape and size to a subsequent shape and size.

As wire is wound around and onto the surface of a former to form a coil, perturbations such as waves are introduced into turns of the coil, each perturbation being formed in a length of the wire less than the full length of a respective turn and projecting along the former surface, the perturbation having an initial shape and size. The coil is taken from the former and fixed in form. A surrounding jacket is radially collapsed onto the wire coil to uniformly press the coil against an internal compressible body in the course of which the overall diameter of the coil is reduced. Resulting stresses in the wire generated during the collapse are relieved by alteration of the perturbations from their initial shape and size to a subsequent shape and size.

An inductor includes a wire and a magnetic layer which has a via, having an inner peripheral surface. On a cross-section across the via, a first point and a second point are located at one side and the other side in a direction in which the first principal surface extends and are kept 50 μm away from a first edge on one side of the inner peripheral surface in the thickness direction, and a third point and a fourth point are located at one side and the other side in the extending direction and are kept 50 μm away from a second edge on the other side of the inner peripheral surface in the thickness direction. An area of a quadrangle having all four points as vertices and an area of the molten solid inside the quadrangle are obtained, along with a percent (S1/S0×100) of the area.

An inductor includes a wire and a magnetic layer which has a via, having an inner peripheral surface. On a cross-section across the via, a first point and a second point are located at one side and the other side in a direction in which the first principal surface extends and are kept 50 μm away from a first edge on one side of the inner peripheral surface in the thickness direction, and a third point and a fourth point are located at one side and the other side in the extending direction and are kept 50 μm away from a second edge on the other side of the inner peripheral surface in the thickness direction. An area of a quadrangle having all four points as vertices and an area of the molten solid inside the quadrangle are obtained, along with a percent (S1/S0×100) of the area.

This method for manufacturing a reactor (10) includes: an assembly manufacturing step for assembling a core-coil assembly provided with a reactor core (20), which comprises an inner-side core part that extends in a first direction and an outer-side core part that extends in a second direction and is linked to the inner-side core part, and a coil (30) that can be disposed around the inner-side core part with a gap therebetween and is wound in a tubular shape extending in the first direction, the external dimensions of the coil (30) in a third direction being configured to correspond to the external dimensions of the outer-side core part in the third direction; an installation step for installing the core-coil assembly in a mold in an orientation in which the third direction extends upward and downward so that the positon of the lowermost part of the coil (30) in the third direction and the position of the lowermost part of the outer-side core part coincide; and an injection molding step for filling at least the gap with an insulation material by injection molding.

This method for manufacturing a reactor (10) includes: an assembly manufacturing step for assembling a core-coil assembly provided with a reactor core (20), which comprises an inner-side core part that extends in a first direction and an outer-side core part that extends in a second direction and is linked to the inner-side core part, and a coil (30) that can be disposed around the inner-side core part with a gap therebetween and is wound in a tubular shape extending in the first direction, the external dimensions of the coil (30) in a third direction being configured to correspond to the external dimensions of the outer-side core part in the third direction; an installation step for installing the core-coil assembly in a mold in an orientation in which the third direction extends upward and downward so that the positon of the lowermost part of the coil (30) in the third direction and the position of the lowermost part of the outer-side core part coincide; and an injection molding step for filling at least the gap with an insulation material by injection molding.