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 method of manufacturing a permanent magnet for a rotor of an axial flux electric machine is described herein. The method includes forming multiple permanent magnet (PM) pieces to have the same shape. Each of the PM pieces has an inner radial surface, an outer radial surface, and a pair of side surfaces extending between the inner and outer radial surfaces. The method further includes attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor.

An apparatus for assembling a repelling magnet combination, comprising a first and second magnet, a first and second holding magnet, a first holding base with a first holding base first end, and a second holding base with a second holding base first end. The first and second holding magnets are positioned at the first and second holding base first ends, and the first and second magnets are magnetically attached to the first and second holding magnets respectively, with outward faces exhibiting like magnetic polarities. The first and second magnets are brought into contact by moving the first and second holding base first ends into close proximity, whereby the first and second holding magnets exert holding forces on the first and second magnets which overcome a repelling force generated therebetween, allowing a repelling force countering means, such as an adhesive, to bond the magnets together into a repelling magnet combination.

An apparatus for assembling a repelling magnet combination, comprising a first and second magnet, a first and second holding magnet, a first holding base with a first holding base first end, and a second holding base with a second holding base first end. The first and second holding magnets are positioned at the first and second holding base first ends, and the first and second magnets are magnetically attached to the first and second holding magnets respectively, with outward faces exhibiting like magnetic polarities. The first and second magnets are brought into contact by moving the first and second holding base first ends into close proximity, whereby the first and second holding magnets exert holding forces on the first and second magnets which overcome a repelling force generated therebetween, allowing a repelling force countering means, such as an adhesive, to bond the magnets together into a repelling magnet combination.

A method of manufacturing a permanent magnet for a rotor of an axial flux electric machine is described herein. The method includes forming multiple permanent magnet (PM) pieces to have the same shape. Each of the PM pieces has an inner radial surface, an outer radial surface, and a pair of side surfaces extending between the inner and outer radial surfaces. The method further includes attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor.

An apparatus for assembling a repelling magnet combination, comprising a first and second magnet, a first and second holding magnet, a first holding base with a first holding base first end, and a second holding base with a second holding base first end. The first and second holding magnets are positioned at the first and second holding base first ends, and the first and second magnets are magnetically attached to the first and second holding magnets respectively, with outward faces exhibiting like magnetic polarities. The first and second magnets are brought into contact by moving the first and second holding base first ends into close proximity, whereby the first and second holding magnets exert holding forces on the first and second magnets which overcome a repelling force generated therebetween, allowing a repelling force countering means, such as an adhesive, to bond the magnets together into a repelling magnet combination.

A method of making an inductor includes forming a plurality of first metal layers on a substrate and an ILD. The method includes patterning a plurality of trenches in the ILD, depositing a magnetic material, and depositing another layer of ILD. The method further includes patterning a plurality of vias adjacent to the trenches filled with the magnetic material, and patterning trenches in the another layer of ILD. The trenches in the another layer of ILD include first portions arranged over, adjacent to and substantially parallel the plurality of first metal layers, and the second portions arranged substantially perpendicular to the first portions, extending from both ends of the first portions, and oriented in opposite directions such that the second portions are continuous with the plurality of vias. The method includes depositing a metal in the plurality of vias and the trenches in the another layer of ILD.

A punch processing method for electrical steel sheets to manufacture core segments includes: stacking a plurality of electrical steel sheets; and punching out the plurality of electrical steel sheets in a stacked state simultaneously to manufacture the core segments, wherein in a case where the core segments are applied to a stator core in which a maximum magnetic flux density at a tooth portion is to be higher than a maximum magnetic flux density at a back yoke portion, degrees of Vickers hardness of an electrical steel sheet located second from a bottom side and above in the stacked state are set to 180 HV or higher, and 10 HV or higher than a value of degree of Vickers hardness of an electrical steel sheet located on the bottom side in the stacked state.

A method for forming an inductor device. The method comprises forming a trench within a central core region of a conductive coil formed within a dielectric material. The method further comprises forming a composite region within the trench. The composite region including a polymer matrix having a plurality of particles with magnetic properties dispersed therein with the central core region to reduce eddy current loss and increase energy storage.

A method for assembling an amorphous metallic transformer core includes providing at least one coil of amorphous metallic strip, unwinding the amorphous metallic strip from the coil, utilizing a roll feed to transport the amorphous strip along a longitudinal direction through a shearing section, along a bridge plate, and into an accumulator roll, advancing a first end of the amorphous strip into the accumulator roll a predetermined distance, stopping the accumulator roll while the roll feed continues to feed the amorphous strip at a set speed, moving the bridge plate from a closed position to an open position, moving a deflector plate from a non-deflecting position to a deflecting position, continuing to operate the roll feed so that a first desired feed length of the amorphous strip is achieved, and shearing the amorphous strip at the first desired feed length to produce an amorphous strip comprising the desired feed length.