Electromagnetic assembly and method of assembling electromagnetic assembly

Abstract

An electromagnetic assembly is provided. The electromagnetic assembly includes a core including a core base and a core top, the core defining a recess sized to receive a winding. The electromagnetic assembly also includes a void spacer including one or more wires positioned between the core base and the core top. The disclosure also relates to a method of assembling the electromagnetic assembly.

Description

Technical Field

[0001] The field of the present disclosure is related to electromagnetic assemblies, and more particularly, to electromagnetic assemblies having wire interstitial spacers and methods of assembling the same. Background Art

[0002] An electromagnetic component may be a device such as a transformer or an inductor. The core of an electromagnetic component includes voids for many different reasons. Known void spacers in electromagnetic components are disadvantageous in certain respects and need to be improved. Summary of the invention

[0003] In one embodiment, an electromagnetic assembly is provided. The electromagnetic assembly includes a core body, the core body including a core base and a core top, the core body defining a recess sized to accommodate a winding. The electromagnetic assembly also includes a gap spacer, the gap spacer including one or more wires positioned between the core base and the core top.

[0004] In another aspect, a method of assembling an electromagnetic assembly is provided. The method includes providing a core body including a core base and a core top, the core body defining a recess sized\designed to accommodate a winding. The method also includes placing a coil in the recess to build the winding. The method also includes positioning an interstitial spacer including one or more wires on the core base and depositing epoxy resin on the core base. Additionally, the method includes assembling the core top with the core base into an electromagnetic assembly, and curing the electromagnetic assembly.

[0005] According to some embodiments of the present disclosure, an electromagnetic assembly includes a core and an interstitial spacer, wherein the core includes a core base and a core top, the core defines a recess sized to receive a winding, and the interstitial spacer includes one or more wires, the interstitial spacer is positioned between the core base and the core top.

[0006] In some embodiments, at least one of the one or more lines is electrically conductive.

[0007] In some embodiments, one or more wires are positioned adjacent to the outer edge of the core base.

[0008] In some embodiments, at least one of the one or more wires is positioned in a recess.

[0009] In some embodiments, at least one of the one or more lines is not electrically conductive.

[0010] In some embodiments, the core base includes a body, a first pillar and a second pillar, the first pillar defines a first pillar surface, and the second pillar defines a second pillar surface, wherein the first pillar and the second pillar extend from the body to the core top, a recess is positioned between the first pillar and the second pillar, and the first pillar surface and the second pillar surface face the core top.

[0011] In some embodiments, one or more wires are positioned on the first strut face and / or the second strut face.

[0012] According to some embodiments of the present disclosure, a method for assembling an electromagnetic component includes providing a core body, the core body including a core base and a core top, the core body defining a recess size to receive a winding; placing a plurality of coils in the recess to construct the winding; positioning a gap spacer, the gap spacer including one or more wires on the core base; depositing epoxy resin on the core base; assembling the core top and the core base to form an electromagnetic component, and curing the electromagnetic component.

[0013] In some embodiments, the method of assembling an electromagnetic assembly is automated.

[0014] In some embodiments, positioning the interstitial spacers further comprises positioning one or more wires outside adjacent to the core base.

[0015] In some embodiments, depositing the epoxy further comprises depositing the epoxy in a dotted pattern.

[0016] In some embodiments, positioning the interstitial spacer further comprises positioning one or more conductive wires on the core base.

[0017] In some embodiments, positioning the interstitial spacer further comprises positioning at least one of the one or more wires in the recess.

[0018] In some embodiments, positioning the interstitial spacers further comprises positioning one or more non-conductive wires on the core base.

[0019] In some embodiments, the core base includes a body, a first leg and a second leg, wherein the first leg defines a first leg face, and the second leg defines a second leg face, wherein the first leg and the second leg extend from the body and a recess positioned between the first leg and the second leg.

[0020] In some embodiments, positioning the interstitial spacer further comprises positioning one or more wires on the first pillar surface and / or the second pillar surface.

[0021] In some embodiments, depositing the epoxy further comprises depositing the epoxy in strips.

[0022] In some embodiments, positioning the interstitial spacers further comprises pressing one or more wires onto the epoxy. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] A non-limiting and non-exhaustive description of embodiments is given with reference to the following drawings, in which like reference numerals refer to like parts in the various drawings unless otherwise specified.

[0024] Figure 1A is a schematic diagram of a known electromagnetic component.

[0025] Figure 1B yes Figure 1A The electromagnetic assembly shown, Figure 1A The core top in the is separated from the rest of the electromagnetic assembly.

[0026] Figure 2A is an example schematic diagram of an electromagnetic component.

[0027] Figure 2B yes Figure 2A The electromagnetic assembly shown, Figure 2A The core top and windings are depicted separately from the rest of the electromagnetic assembly.

[0028] Figure 2C is an example schematic diagram of another electromagnetic component.

[0029] Figure 2D yes Figure 2C The electromagnetic assembly shown, Figure 2C The core top and windings are depicted separately from the rest of the electromagnetic assembly.

[0030] Figure 3A is an example schematic diagram of another electromagnetic component.

[0031] Figure 3B yes Figure 3A The electromagnetic assembly shown, Figure 3A The core top in is depicted separately from the rest of the electromagnetic assembly.

[0032] Figure 4 yes Figure 2A-Figure 3B A block diagram of an example method of assembling an electromagnetic assembly is shown.

[0033] Figure 5 Demonstrating the electromagnetic components disclosed herein and Figure 1A Test results comparing the effectiveness of known electromagnetic components are shown.

[0034] The reference numerals are described as follows:

[0035] 100,200,200-A,200-C,200-3: Electromagnetic components

[0036] 102,202: Core

[0037] 104,204: Core base

[0038] 106,206: Core top

[0039] 108: Gap spacer

[0040] 110: Gap

[0041] 112: Noodles

[0042] 114: Epoxy resin

[0043] 208: Main body

[0044] 210: Pillar

[0045] 210-1: The First Pillar

[0046] 210-2: Second Pillar

[0047] 210-w: Winding support

[0048] 210-nw: Non-winding support

[0049] 212: Pillar surface

[0050] 212-1: First Pillar Face

[0051] 212-2: Second Pillar Surface

[0052] 214: Depression

[0053] 216: Gap spacer

[0054] 217: Gap

[0055] 218: Line

[0056] 220: Winding

[0057] 222: Outside

[0058] 224: Central Area

[0059] 226: Epoxy resin

[0060] 400: Methods

[0061] 402: Provided

[0062] 403: Place

[0063] 404: Location

[0064] 406: Deposition

[0065] 408: Assembly

[0066] 410: Curing

[0067] 502: Table

[0068] 504: Graph DETAILED DESCRIPTION

[0069] The present disclosure includes electromagnetic assemblies and methods of assembling electromagnetic assemblies. As used herein, an electromagnetic assembly is an assembly including a core and a winding wound around the core, and a current is passed through the winding to generate a magnetic flux in the core. The electromagnetic assembly can be assembled as a transformer or an inductor. The inductor is described as an example for illustrative purposes only. The assemblies and methods described herein can be generally applied to electromagnetic assemblies. Method implementations will be discussed in part in the following description, which will be apparent and in part explicitly discussed.

[0070] Gaps are defined in electromagnetic components for various reasons, such as to prevent electromagnetic component saturation. Gaps are usually placed on the mating surface of the core material. Gaps can be ground into the legs of the core, or formed by including gap spacers in the core.

[0071] Figure 1A 1 is a schematic diagram of a known electromagnetic assembly 100. The electromagnetic assembly 100 includes a core 102 having a core base 104 and a core top 106. The electromagnetic assembly 100 includes a gap spacer 108 positioned between the core base 104 and the core top 106 to define a gap 110. The gap spacer 108 is generally made of a non-magnetic and non-electrically conductive material, such as paper or The material is paper-like and impregnated with epoxy resin.

[0072] In assembling the electromagnetic assembly, the desired shape of the gap spacer 108 is punched out. The gap spacer 108 is then manually placed on the face 112 of the core base 104. Epoxy 114 is deposited on the core base 104. The core top 106 and the core base 104 are assembled together. The electromagnetic assembly 100 is then placed in a microwave oven to cure the epoxy 114, so that it is hardened by the epoxy 114 to bond between the core base 104 and the core top 106.

[0073] The process of the known electromagnetic assembly 100 is expensive and time consuming because the placement of the gap spacer 108 requires tedious manual labor, and automation cannot meet the relatively strict inductance tolerance of the electromagnetic assembly 100. The material of the gap spacer 108 is in a set thickness and only a limited number of set thicknesses are commonly available, such as 0.5 mils (0.013 mm), 1 mil (0.025 mm), 3 mils (0.076 mm), 5 mils (0.13 mm), 10 mils (0.25 mm), 15 mils (0.38 mm) or 20 mils (0.51 mm). The material of the gap spacer is prone to folds or creases, and the thickness at the folds or creases may increase by two or more times. Because the inductance of the electromagnetic assembly has a relatively strict tolerance, the tolerance for the thickness of the gap spacer is relatively strict. For example, the tolerance of the inductance should be 5-6σ, where 5σ is 233ppm and 6σ is 3.4ppm. σ is the standard deviation of the inductance from the expected value, and ppm represents the number of defective products per million manufactured products. Increasing the thickness of the gap spacer by two or more times may increase the error to 2000ppm, making the electromagnetic component unable to meet the expected application. Therefore, it is necessary to be very careful when placing the gap spacer to ensure that the gap spacer is placed at the desired position on the core, and more importantly, no folds or creases exist in the gap spacer. In addition, since the material thickness of the gap spacer 108 is a limited set thickness, if the desired thickness of the gap spacer 108 is not among the limited available thicknesses, assembling two or more material sheets of different thicknesses is required to make the gap spacer 108 have the desired thickness. Similarly, since the inductance tolerance of the electromagnetic component is relatively strict, the process of assembling multiple sheets is cumbersome and requires great care to ensure that there are no folds or creases. Although the deposition of epoxy resin can be automated, the only available manufacturing process for constructing a gap in the core through the gap spacer 108 is made manually. The machine is unable to pick up the gap spacers cut from relatively thin paper-like materials, place the cut material in a precise position on the core without any folds and creases, or sometimes assemble two or more pieces of material to construct a gap spacer with a desired thickness.

[0074] Furthermore, because gap spacer 108 is relatively thin, when core base 104 and core top 106 are placed together and pressed on epoxy 114 , epoxy 114 may travel over and / or under gap spacer 108 , also affecting the thickness of gap 110 and the inductance of electromagnetic assembly 100 .

[0075] In contrast, the components and methods disclosed herein solve the above-mentioned problems in known electromagnetic components and known assembly methods of electromagnetic components. Wire is used as a gap spacer. The wire specifications, such as American Wire Gauge (AWG) or Metric wire specifications, are in very small increments. Wires of various specifications, especially conductive wires, are readily available even at manufacturing plants and distributors of wires, especially at manufacturing plants of electromagnetic components. Therefore, changing the thickness of the gap spacer can be achieved by simply selecting wires of different specifications. In addition, the epoxy flows around the wire without affecting the gap of the electromagnetic component and the inductance of the electromagnetic component. The wire placed on the core will not be folded or creased. The assembly method described herein can be automated without affecting the strict tolerances for meeting the inductance of the electromagnetic component.

[0076] Figure 2A-2D Showing example electromagnetic assembly 200-A ( Figure 2A and Figure 2B )、200-C( Figure 2C and Figure 2D In this embodiment, the electromagnetic component 200 includes a core 202. The core 202 includes a core base 204 and a core top 206. Figure 2A-2D The illustrated core 202 is a UI core, in which the core base 204 is shaped like the letter U and the core top is shaped like the letter I. The core base 204 includes a body 208 and one or more pillars 210 . Figure 2A-2D The core base 204 shown includes a first leg 210-1 and a second leg 210-2. The first leg 210-1 defines a first leg face 212-1, and the second leg 210-2 defines a second leg face 212-2. The leg 210 extends from the body 208. The core body 202 defines a recess 214 that is sized to receive a winding 220 therethrough. The recess 214 may be defined in the core base 204, the core top 206, or both (see the description below). Figure 3A and Figure 3B The recess 214 is located between the first support 210 - 1 and the second support. When assembled, the support 210 extends toward the core top 206 , and the support surface 212 faces the core top 206 .

[0077] In this example embodiment, the electromagnetic assembly 200 includes a gap spacer 216 for the gap 217. The gap spacer 108 includes one or more wires 218. The wire 218 having a circular cross-section is shown as an example for illustration purposes only. The cross-section of the wire 218 can be other shapes that enable the electromagnetic assembly 200 to function as described herein, such as square or rectangular. The wire 218 can be conductive or non-conductive. Exemplary wires can be magnetic wires, such as wires made of copper, aluminum, steel and / or other materials. The wires can be coated with an insulator or not. Exemplary non-conductive wires can be fishing lines. Even in a manufacturing plant, wires of different gauges, especially conductive wires, can be readily available in very small increments. Therefore, the gap 217 defined by the gap spacer 108 is easily sized to meet the tight tolerances of the inductance of the electromagnetic assembly 200, thereby eliminating the cumbersome manual process of assembling multiple sheets to the desired thickness in known methods. Only two wires 218 ( Figure 2B and 2D , also refer to Figure 3B ). Other numbers of wires, such as one or three, may be used to enable electromagnetic assembly 200 to function as described herein. The length of wire 218 may be less than the size of core 202 (see Figure 2B ). The length of the wire 218 may be substantially the same as the size of the core 202 (see Figure 2D ). Wire 218 may have other lengths that enable the electromagnetic assembly to function as described herein.

[0078] In this example embodiment, wire 218 may be positioned on support face 212 of support 210 ( Figure 2B The entire length of the wire 218 may be positioned on the support surface 212. The wire 218 may be placed across the recess 214 with one end positioned on the first support surface 212-1 and the other end positioned on the second support surface 212-2 ( Figure 2D ). When a high frequency alternating current (AC) signal is provided to the winding 220 and the wire 218 is a conductive material, losses from eddy currents in the wire 218 occur. Placing the wire 218 across the recess 214 reduces losses from eddy currents compared to placing the wire 218 on the support face 212 because less magnetic flux flows through the wire 218 when the wire 218 is placed on the recess 214 than when the wire 218 is placed on the support face 212. For AC applications, the wire 218 may be placed beside the outer edge 222 of the core base 204 to reduce eddy current losses in AC signals because the magnetic flux is reduced at a location away from the central region 224 of the core 202, where the winding 220 surrounds the core 202. For direct current (DC) applications, the wire may be placed anywhere on the support face 212.

[0079] In this example embodiment, the electromagnetic assembly 200 also includes epoxy 226, which flows around the wires 218 before curing without affecting the thickness of the gaps 217. The epoxy 226 can be deposited in any pattern, such as stripes ( Figure 2B and Figure 2D ) or dot-shaped (described later in Figure 3B ). The deposition of epoxy 226 can be performed by a machine such as a pneumatic dispenser, where the epoxy is dispensed by a syringe when the pedal of the dispenser is pressed. Dot dispensing is easier to control than strip dispensing. For example, a strip of epoxy can be advanced to the windings and bond the windings to the core 202. The windings are made of a material such as copper, which has a much larger coefficient of thermal expansion (CTE) than the material of the core 202. During operation of the electromagnetic assembly 200, the core 202 may detach from the windings 220 due to the large difference in CTE, which may impair the performance of the electromagnetic assembly 200.

[0080] Figure 3A and Figure 3B Another example electromagnetic assembly 200-3 is shown. The winding 220 is not shown. Figure 3A and Figure 3B The core 202 is an ER-ER core. In some known methods, the gap is constructed by grinding some of the pillars 210 to the desired length. The grinding process needs to be strictly controlled to meet the tight tolerances of the inductance, which may not be practical for relatively small gaps. In other known methods, known gap spacers 108 are used, which have the problems of being difficult to manufacture and not suitable for automation as described above.

[0081] In this example embodiment, the core base 204 includes a winding leg 210-w and a non-winding leg 210-nw. The winding leg refers to a leg arranged to be wound by the winding 220 (see Figure 2A and 2B ). A non-winding leg refers to a leg that is not arranged to be wound by winding 220. Alternatively, wire 218 may be placed across recess 214, with one end of wire 218 positioned on first leg face 212-1 of first leg 210-1 and the other end of wire 218 positioned on second leg face 212-2 of second leg 210-1. The gap 217 defined by gap spacer 216 may be adjusted to a desired size by selecting wire 218 having a specification corresponding to the desired gap size.

[0082] UI core 202( Figure 2A-2D ) and ER-ER core 202( Figure 3A and Figure 3B ) are described herein for illustrative purposes only. The components and methods disclosed herein can be applied to any electromagnetic components having any core shape or any assembly of core shapes, such as EI, ER, ERI or PQI magnetic cores.

[0083] Figure 4 4 is a flow chart of an example method 400 for assembling an electromagnetic assembly. In this example embodiment, method 400 includes providing 402 a core. Method 400 also includes placing 403 a coil in a recess of a core base of the core to build a winding. In addition, method 400 includes positioning 404 a gap spacer including one or more wires on the core base. Method 400 includes depositing 406 epoxy on the core base. Epoxy 226 can be deposited in various patterns, such as in a dot pattern and / or in strips. Epoxy 226 can be positioned before positioning gap spacers 216. For example, epoxy 226 can be deposited before positioning gap spacers 216 on core base 204 so that gap spacers 216 can be pressed onto epoxy 226. Because epoxy 226 is viscous, depositing epoxy before positioning gap spacers 216 can help fix the position of gap spacers 216 on core base 204. Alternatively, the epoxy 226 may be deposited after the interstitial spacers 216 are placed on the core base. For example, the deposition of the epoxy 226 and the placement of the interstitial spacers 216 may be performed at the same station. After the interstitial spacers 216 are positioned on the core base 204, the epoxy 226 is deposited on the interstitial spacers 216, at least partially covering the interstitial spacers 216, without moving the core base 204 or the interstitial spacers 216.

[0084] In this example embodiment, method 400 includes assembling 408 the core top and the core base to form an electromagnetic assembly. The core top 206 and the core base 204 can be assembled together by pressing the core top 206 onto the core base 204. The viscous epoxy 226 bonds the core top 206 to the core base 204. Method 400 also includes curing 410 the electromagnetic assembly. For example, the electromagnetic assembly 200 can be cured in an oven to harden the epoxy 226 and cure the bond between the core top 206 and the core base 204.

[0085] The method 400 may be partially or fully automated, wherein at least a portion of the method 400 is performed by a machine or assembly line, particularly positioning 404 the gap spacer on the core base. Automatically positioning 404 the gap spacer on the core base facilitates the production of a robust electromagnetic assembly and significantly reduces the cost of tedious manual labor in known electromagnetic assemblies and known methods of assembling electromagnetic assemblies.

[0086] Electromagnetic assembly 200-C and Figure 1A The efficiency of the known electromagnetic assembly 100 is shown as The electromagnetic assembly 200 and the conventional electromagnetic assembly 100 were tested at three input voltages of 7Vdc, 12Vdc and 14Vdc, two output voltages of 0.99Vdc and 1.99Vdc, three ambient temperatures of -40°C, 25°C and 130°C, and an output current range of 0 to 40Adc. Figure 5 A table 502 listing the efficiencies of the electromagnetic assembly 200 and the known electromagnetic assembly 100 is shown, as well as a graph 504 showing a worst-case example for an input voltage of 14V, an output voltage of 1.99V, and an ambient temperature of 130°C. In the worst-case scenario, the effect of the losses added by the wires is minimal. From 0 to 40Adc, the losses added by the air gap spacer 216 are significant at low output currents and negligible at high output currents. The losses include i) winding losses, which are proportional to the square of the DC current multiplied by the winding resistance; ii) core losses, which are a function of the AC signal frequency and the AC excitation current; and iii) eddy current losses of the air gap spacer 216 due to the AC excitation current. For a given input voltage and a given output voltage of the electromagnetic assembly, the AC excitation current remains the same. In the worst-case example shown in the graph 504, the eddy current losses reach a maximum value. At low output currents, the losses are mainly determined by the winding losses. Therefore, the significant losses of the air gap spacer 216 at low currents do not significantly affect the performance of the electromagnetic assembly 200.

[0087] Because wires cause eddy current losses from AC signals, especially high frequency AC signals, ordinary technicians are reluctant to use wires as gap spacers for electromagnetic components. By placing wire 218 near the outer edge 222 of core base 204, the losses caused by eddy currents are reduced. By placing wire 218 on recess 214, the losses caused by eddy currents can be further reduced.

[0088] However, the gap spacer with wire greatly improves the manufacturing speed and reliability of the product. The manufacturing process can be fully automated without affecting the quality of the electromagnetic component. Even in the manufacturing plant, wires of different specifications, especially wires, can be readily available in very small increments. If gap spacers of different thicknesses are required, wires of corresponding thicknesses can be easily selected or ordered from the facility, thereby eliminating the cumbersome manual process of adjusting the thickness of the gap spacer by assembling multiple material sheets for the gap. The flexibility of the electromagnetic component design is increased and the manufacturing cost is reduced. In addition, the wire will not fold or crease, thereby eliminating the cumbersome manual process of ensuring that there are no folds or creases in the gap spacers placed in the manufacturing of known electromagnetic components. In addition, since the epoxy resin flows around the wire without affecting the thickness of the gap, the effect of the epoxy resin on the inductance of the electromagnetic component is reduced. In addition, the processes required for known electromagnetic components, such as cutting, stamping or punching the material into the desired shape of the gap spacer, are eliminated. The placement of the wire does not have to be precise, especially for DC electromagnetic components or non-conductive wires. Therefore, the electromagnetic components described herein can be assembled in a robust and simplified manner. The assembly process of the electromagnetic components described herein may be fully or partially automated without compromising the quality of the electromagnetic components.

[0089] At least one technical effect of the systems and methods described herein includes: (a) using wire as a gap spacer of an electromagnetic component; (b) the gap spacer includes a conductive wire; (c) the gap spacer includes a non-conductive wire; (d) positioning the gap spacer including the conductive wire to reduce the loss of high-frequency AC signals caused by eddy currents; and (e) an automated assembly method for the electromagnetic component.

[0090] Exemplary embodiments of electromagnetic assemblies and methods of assembling the same are described in detail above. The systems and methods are not limited to the specific embodiments described herein, but rather, the components of the systems and / or operations of the methods may be used independently and separately from other components and / or operations described herein. In addition, the components and / or operations described may also be defined in other systems, methods and / or devices, or used in combination with other systems, methods and / or devices, and are not limited to being practiced using only the systems described herein.

[0091] As used herein, elements or steps recorded in singular form and beginning with the word "a" or "an" should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recorded. In addition, reference to "examples" or "an example" of the present disclosure is not intended to be interpreted as excluding the existence of additional examples that also incorporate the listed features. In addition, with respect to the terms "including," "comprising," "having," "containing," and variations thereof used herein, these terms are intended to be included as open concepts in a manner similar to the term "comprising."

[0092] Although specific features of various embodiments of the present invention may be shown in some drawings and not in other drawings, this is only for convenience. According to the principles of the present invention, any feature of a drawing may be combined with any feature of any other drawing to reference and / or claim protection.

[0093] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. An electromagnetic component, characterized in that: include: A core body, including a core base and a core top, the core body defining a recess, the recess being sized to receive a winding; as well as A gap spacer, including one or more wires, is placed between the core base and the core top.

2. The electromagnetic assembly of claim 1, wherein at least one of the one or more wires is electrically conductive.

3. The electromagnetic assembly of claim 1, wherein the one or more wires are positioned adjacent an outer edge of the core base.

4. The electromagnetic assembly of claim 1, wherein at least one of the one or more wires is positioned in the recess.

5. The electromagnetic assembly of claim 1, wherein at least one of the one or more wires is electrically non-conductive.

6. The electromagnetic assembly of claim 1, wherein the core base comprises: One subject; a first pillar, defining a first pillar surface; as well as a second pillar, defining a second pillar face, The first pillar and the second pillar extend from the main body to the core top, the recess is positioned between the first pillar and the second pillar, and the first pillar surface and the second pillar surface face the core top.

7. The electromagnetic assembly of claim 6, wherein the one or more wires are placed on the first support surface and / or the second support surface.

8. A method for assembling an electromagnetic assembly, characterized in that: include: Providing a core body, the core body comprising a core base and a core top, the core body defining a recessed size to receive a winding; placing a plurality of coils in the recess to construct the winding; positioning a gap spacer comprising one or more wires on the core base; depositing an epoxy resin on the core base; Assembling the core top and the core base to form an electromagnetic assembly; as well as The electromagnetic assembly is cured.

9. The method of assembling an electromagnetic assembly of claim 8, wherein the method of assembling an electromagnetic assembly is automated.

10. The method of assembling an electromagnetic assembly of claim 8, wherein positioning the interstitial spacer further comprises positioning one or more of the wires adjacent an outer edge of the core base.

11. The method of assembling an electromagnetic assembly of claim 8, wherein depositing the epoxy further comprises depositing the epoxy in a dot pattern.

12. The method of assembling an electromagnetic assembly of claim 8, wherein positioning the interstitial spacer further comprises positioning one or more conductive wires on the core base.

13. The method of assembling an electromagnetic assembly of claim 8, wherein positioning the interstitial spacer further comprises positioning one or at least one of the plurality of wires in the recess.

14. The method of assembling an electromagnetic assembly of claim 8, wherein positioning the interstitial spacer further comprises positioning one or more non-conductive wires on the core base.

15. The method of assembling an electromagnetic assembly of claim 8, wherein the core base comprises: One subject; a first pillar, defining a first pillar surface; as well as a second pillar, defining a second pillar face, The first and second struts extend from the body and the recess positioned between the first and second struts.

16. The method of assembling an electromagnetic assembly of claim 15, wherein positioning the interstitial spacer further comprises placing the one or more wires on the first support surface and / or the second support surface.

17. The method of assembling an electromagnetic assembly of claim 8, wherein depositing the epoxy further comprises depositing the epoxy in a stripe shape.

18. The method of assembling an electromagnetic assembly of claim 8, wherein positioning the interstitial spacer further comprises pressing the one or more wires onto the epoxy.

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