A method of fabricating an electric machine stator includes inserting one or more electrical coils into a form and partially curing the one or more electrical coils. The method also includes populating the electric machine stator with the one or more electrical coils and curing the electric machine stator with one or more electrical coils.

A method to form a choke is disclosed, wherein the method comprises: encapsulating a hollow coil by a molding body; forming a first core, wherein the first core comprises a pillar; and disposing at least one first portion of the pillar inside the encapsulated hollow coil. The method avoids the overflow or vertical flow issue during a molding process for encapsulating a coil that has been wound on a core already.

In an armature coil according to the present invention and, more particularly, in an armature coil including a plurality of coil conductors wound around a plurality of slots which are formed in a stator core and opened on the radially inner side, the circumferential width of the plurality of the coil conductors is formed in a substantially trapezoidal shape which gets narrower toward the radially inner side and the cross-sectional areas of the plurality of the coil conductors in the slot are each substantially the same and the circumferential width thereof is formed narrower as the coil conductor is arranged toward the radially inner side; and one coil conductor is formed in a convex shape and another coil conductor is formed in a concave shape along the convex shape.

A method making a three-dimensional inductor, the method including: forming a plurality of vias in a substrate or a molding compound, wherein the vias are arranged with spacings among them; forming a metal layer having interconnects, wherein the interconnects of the metal layer connect the plurality of vias on one end of the vias; forming a plurality of wires to connect the plurality of vias on the other end of the vias to form the 3D inductor; and tuning one or more of the plurality of wires to adjust a physical configuration and inductance value of the 3D inductor.

A stator manufacturing method in which a coil including a plurality of coil units formed by winding a rectangular wire is fitted in a cylindrical core having a plurality of slots extending in a radial direction and opening in a core inner peripheral surface so that the slots are distributed in a circumferential direction, the rectangular wire being a linear conductor having a rectangular section.

The present invention relates to a coil type unit for wireless power transmission, a wireless power transmission device, an electronic device, and a manufacturing method of a coil type unit for wireless power transmission. A coil type unit for wireless power transmission according to the present invention includes a coil pattern in the form of a wiring pattern; a magnetic portion having the coil pattern attached to one surface thereof; and an adhesive portion interposed between the magnetic portion and the coil pattern to bond the magnetic portion and the coil pattern, wherein the magnetic portion is formed by laminating one or more conductive sheets with one or more magnetic sheets and integrally firing the laminated sheets, and the magnetic portion has conductive holes in the position, where both ends of the coil pattern are disposed, to electrically connect the both ends of the coil pattern and the conductive sheet.

An inductor device includes a substrate, and a plurality of first trenches including a first metal on the substrate to form first metal layers. The first metal layers are arranged substantially parallel to the substrate. A plurality of second trenches including a second metal is over the first metal layers and includes first portions and second portions. The first portions are substantially parallel to and interdigitate the first metal layers. The second portions are substantially perpendicular to the first portions, extend from ends of the first portions, and are oriented in opposite directions such that the second portions extend over ends of adjacent first metal layers. A plurality of vias connects the first metal layers to the second metal layers. A plurality of magnetic trenches is over the first metal layers, under the second metal layers, and substantially parallel to the second portions of the plurality of second trenches.

A coil insertion device includes: a pair of delivery jigs respectively formed with slits into which a pair of side portions of a coil that are parallel with each other can be inserted; and a side portion inserting mechanism configured to push out the side portions inserted into the slits from the slits to insert the side portions into slots of a stator core, the slots facing the slits, the side portion inserting mechanism has: pushing blocks inserted into the slits; and a pushing block moving mechanism configured to move the pushing blocks in a depth direction of the slits.

A power transformer includes at least two first windings, at least two second windings interleaved with the at least two first windings, and a magnetic core. The at least two first windings and the at least two second windings are positioned adjacent the magnetic core. Each first winding includes a wire and a plurality of turns. One or more windings of the at least two first windings include a bonding material and at least two adjacent turns of said plurality of turns adhered to each other via the bonding material. Other example power transformers, methods of manufacturing power transformers, and methods of manufacturing windings are also disclosed.

A method of manufacturing a coil includes forming a wound body by winding a coil wire in multiple layers, and forming a coil by pressing the wound body using a die surrounding the wound body and compressively deforming the wound body. The wound body has a contour of a rectangular or substantially rectangular shape in cross section, and includes coil wire portions located in the cross section of the coil wire, the coil wire portions being aligned along each side of the rectangular or substantially rectangular shape. The coil has a contour of a fan shape or approximate fan shape in the cross section, where the coil wire portions are aligned in a direction along an arc and a radial direction of the fan shape or approximate fan shape.