Electrical Isolation Device Capable Of Limiting Magnetic Saturation Even Upon Receipt Of High Power DC Bias And Method For Making The Same

Abstract

An electrical device is produced by winding wires around a core. The device may be used as a transformer. Wires are inserted into, through and around a first hole and a first side of a core a desired number of times. Thereafter, the wires are extended along either a top or a bottom of the core and then passed through and around a second hole of the core. After the wires are wound around the second hole of the core and a second side of the core, the production of the device is complete.

1 . A method for producing an electric device, the method comprising:
 inserting at least a first wire through a first hole in a core;   wrapping the first wire around a first side of the core;   inserting at least a second wire through a second hole in the core, the second hole being spaced from the first hole and having a long axis extending substantially parallel to a long axis of the first hole; and   wrapping the second wire around a second side of the core, the second side being spaced from the first side.   
   
   
       2 . The method as recited in  claim 1 , wherein the first and second wires each comprise four wires. 
   
   
       3 . The method as recited in  claim 1 , further comprising:
 performing both steps of inserting and both steps of wrapping a defined number of times.   
   
   
       4 . The method as recited in  claim 1 , wherein the core is substantially a cut-off ellipsoid. 
   
   
       5 . The method as recited in  claim 1 , wherein the core has substantially a racetrack cross-section. 
   
   
       6 . The method as recited in  claim 1 , wherein the first and second wires are part: of a single wire and the method further comprises extending the first wire over a top or bottom of the core after the wrapping the first wire around the first side of the core. 
   
   
       7 . An electrical device produced by a method of:
 inserting at least a first wire through a first hole in a core;   wrapping the first wire around a first side of the core;   inserting at least a second wire through a second hole in the core, the second hole being spaced from the first hole and having a long axis extending substantially parallel to -a long axis of the first hole; and   wrapping the second wire around a second side of the core, the second side being spaced from the first side.   
   
   
       8 . The method as recited in  claim 7 , wherein the first and second wires are part of a single wire and the method further comprises extending the first wire over a top or bottom of the core after the wrapping the first wire around the first side of the core. 
   
   
       9 . A connector for enabling electrical communication with a plug, the connector comprising:
 a set of contacts;   a filter circuit in communication with the set of contacts; and   a set of terminals in communication with the filter circuit,   wherein the filter circuit includes a transformer with a core, the transformer produced by the steps of:   inserting at least a first wire through a first hole in the core;   wrapping the first wire around a first side of the core;   inserting at least a second wire through a second hole in the core, the second hole being spaced from the first hole and having a long axis extending substantially parallel to a long axis of the first hole; and   wrapping the second wire around a second side of the core, the second side being spaced from the first side.   
   
   
       10 . The connector as recited in  claim 9 , wherein the core is substantially a cut-off ellipsoid. 
   
   
       11 . The method as recited in  claim 9 , wherein the first and second wires are part of a single wire and the method further comprises extending the first wire over a top or bottom of the core after the wrapping the first wire around the first side of the core. 
   
   
       12 . A method for producing an electrical device, the method comprising:
 wrapping a &a and second wire around a first core;   inserting the first and second wire and a third and a fourth wire through a first hole in a second core;   wrapping the first, second, third and fourth wires around a first side of tie second core;   inserting fifth, sixth, seventh and eighth wires through a second hole in the second core, the second hole being spaced from the first hole and having a long axis extending substantially parallel to a long axis of the first hole;   wrapping the fifth, sixth, seventh and eighth wires around a second side of the second core, the second side being spaced from the first side; and   wrapping the fifth and sixth wires around the first core.   
   
   
       13 . The method as recited in  claim 12 , wherein the first core is a toroid. 
   
   
       14 . The method as recited in  claim 12 , wherein the second core is substantially a cut-off ellipsoid. 
   
   
       15 . The method as recited in  claim 12 , wherein the first and fifth wires are part of a single wire, the second and sixth wires are part of a single wire, the third and seventh wires are part of a single wire, the fourth and eighth wires are part of a single wire, and the method further comprises extending the first, second, third and fourth wires over a top or bottom of the second core after the wrapping the first, second, third and fourth wires around the first side of the second core. 
   
   
       16 . A connector for enabling electrical communication with a plug, the connector comprising:
 a set of contacts;   a filter circuit in communication with the set of contacts; and   a set of terminals in communication with the filter circuit;,   wherein the filter circuit is produced by the steps of:   wrapping a first and second wire around a first core;   inserting the first and second wire and a third and a fourth wire through a first hole in a second core;   wrapping the first, second, third and fourth wires around a first side of the second core;   inserting fifth, sixth, seventh and eighth wires through a second hole in the second core, the second hole being spaced from the first hole and having a long axis extending substantially parallel to a long axis of the first hole;   wrapping the fifth, sixth, seventh and eighth wires around a second side of the second core, the second side being spaced from the first side; and   wrapping the fifth and sixth wires around the first core.   
   
   
       17 . The connector as recited in  claim 16 , wherein the first and fifth wires are part of a single wire, the second and sixth wires are part of a single wire, the third and seventh wires are part of a single wire, the fourth and eighth wires are part of a single wire, and wherein the filter circuit is further produced by extending the first, second, third and fourth wires over a top or bottom of the second core after the wrapping the first, second, third and fourth wires around the first side of the second core. 
   
   
       18 . An electrical device comprising:
 a body having first and second holes extending therethough, the holes being spaced from one another and having longitudinal axes extending substantially parallel to one another;   at least one wire extending through the first hole, the wire wrapped around a first side of the body;   at least a second wire extending through the second hole in the body and wrapped around a second side of the body, the second side being spaced from the first side.