There is provided an insulated electric wire formed by covering a rectangular conductor wire having a rectangular cross-sectional shape with an insulating film. The insulating film is formed of an inner layer covering a surface of the rectangular conductor wire, and an outer layer covering a surface of the inner layer. A thickness (t.sub.1) of a section of the inner layer, which covers one short side of two facing short sides of the same length of a rectangular cross section of the rectangular conductor wire, is greater than a thickness (t.sub.2) (including that t.sub.2=0) of a section of the inner layer which covers the other short side. An elastic modulus and/or a yield stress of the inner layer are less than an elastic modulus and/or a yield stress of the outer layer.

There is provided an insulated electric wire formed by covering a rectangular conductor wire having a rectangular cross-sectional shape with an insulating film. The insulating film is formed of an inner layer covering a surface of the rectangular conductor wire, and an outer layer covering a surface of the inner layer. A thickness (t.sub.1) of a section of the inner layer, which covers one short side of two facing short sides of the same length of a rectangular cross section of the rectangular conductor wire, is greater than a thickness (t.sub.2) (including that t.sub.2=0) of a section of the inner layer which covers the other short side. An elastic modulus and/or a yield stress of the inner layer are less than an elastic modulus and/or a yield stress of the outer layer.

A bifilar winding system for the manufacture of poloidal field superconducting magnets for nuclear fusion includes two superconducting coil winding production lines which are symmetrically arranged, a dropping fixture, a rotary platform and a winding mold, and an automatic control system. Each of the two winding production lines includes a conductor unwinding device, a straightener, an ultrasonic cleaning machine, a sandblasting and cleaning machine, a bending machine, an inter-turn insulation taping machine. During the winding of a coil, a superconducting conductor is unwound by the conductor unwinding device under the control of the automatic control system, then straightened, ultrasonically cleaned, sandblasted and cleaned, and bent into a desired radius, then wrapped with multiple layers of insulating tape by the inter-turn insulation taping machine, and finally fixed, by the dropping fixture, precisely on the rotary platform at a correct position within a profile of the winding mold.

A bifilar winding system for the manufacture of poloidal field superconducting magnets for nuclear fusion includes two superconducting coil winding production lines which are symmetrically arranged, a dropping fixture, a rotary platform and a winding mold, and an automatic control system. Each of the two winding production lines includes a conductor unwinding device, a straightener, an ultrasonic cleaning machine, a sandblasting and cleaning machine, a bending machine, an inter-turn insulation taping machine. During the winding of a coil, a superconducting conductor is unwound by the conductor unwinding device under the control of the automatic control system, then straightened, ultrasonically cleaned, sandblasted and cleaned, and bent into a desired radius, then wrapped with multiple layers of insulating tape by the inter-turn insulation taping machine, and finally fixed, by the dropping fixture, precisely on the rotary platform at a correct position within a profile of the winding mold.

An assembly and method of manufacturing the coil assembly is provided. The method includes acquiring a sheet of a conductive metal and producing a plurality of coils from the sheet of conductive metal. Further, the method includes layering at least two of the plurality of coils with an insulation layer there between to construct the coil assembly and electrically coupling the at least two of the plurality of coils within the coil assembly.

An assembly and method of manufacturing the coil assembly is provided. The method includes acquiring a sheet of a conductive metal and producing a plurality of coils from the sheet of conductive metal. Further, the method includes layering at least two of the plurality of coils with an insulation layer there between to construct the coil assembly and electrically coupling the at least two of the plurality of coils within the coil assembly.

The invention comprises a method of: providing an inductor core, placing a winding guide within an inch of the inductor core, positioning a first turn element with the winding guide, positioning a second turn element with the winding guide, and mechanically coupling the first turn element to the second turn element to form at least a part of a winding, the winding forming a wrapped shape about the inductor core. Optionally and preferably, turn elements are subsequently joined, mechanically coupled, and/or welded together to form sections of the winding.

The invention comprises a method of: providing an inductor core, placing a winding guide within an inch of the inductor core, positioning a first turn element with the winding guide, positioning a second turn element with the winding guide, and mechanically coupling the first turn element to the second turn element to form at least a part of a winding, the winding forming a wrapped shape about the inductor core. Optionally and preferably, turn elements are subsequently joined, mechanically coupled, and/or welded together to form sections of the winding.

A coil for transfer of information or energy is described. The coil includes an electrically conductive magnetically insulative first layer and a magnetically conductive second layer bonded to the first layer along the length of the first layer. The first and second layers are wound to form a plurality of substantially concentric loops. A width and a length of the second layer may be substantially co-extensive with a respective width and length of the first layer so as to expose opposing longitudinal edge surfaces of the first layer along the length of the first layer. At least one of the opposing longitudinal edge surfaces may include a regular pattern extending substantially along a same first direction and across substantially the entire coil. A method of making the coil is described.

A coil for transfer of information or energy is described. The coil includes an electrically conductive magnetically insulative first layer and a magnetically conductive second layer bonded to the first layer along the length of the first layer. The first and second layers are wound to form a plurality of substantially concentric loops. A width and a length of the second layer may be substantially co-extensive with a respective width and length of the first layer so as to expose opposing longitudinal edge surfaces of the first layer along the length of the first layer. At least one of the opposing longitudinal edge surfaces may include a regular pattern extending substantially along a same first direction and across substantially the entire coil. A method of making the coil is described.