A method of making an EMR coil assembly having a split housing including a coil-retaining body member and ring member attached thereto, the EMR coil assembly including a coil having a plurality of polyimide face sheets disposed between a polyester face sheet forming the outer wear surface of the coil and a major surface of the coil.

An electromagnetic dent remover including a dent removal head containing an electromagnetic work coil capable of creating a locally concentrated magnetic field when first energized by a slow rising current followed by a fast pulsing counter current is disclosed. The electromagnetic work coil comprises a cylinder formed of a spirally wound metal strip whose convolutions are electrically insulated from one another by coatings or layers of electrical insulation. In one form, slots and holes, located in the walls of the coil, control the electrical current density within the coil to thereby produce the desired locally concentrated magnetic field. In another form, the ends of the coils are machined such that at least one magnetic field concentration projection projects outwardly from one annular end of the coil. The other end of the coil is machined such that it is a mirror image of the projection end. In either form the electromagnetic work coil is encased in a nonmagnetic housing, which may be formed by encapsulation.

An induction heating coil having fluoroplastic coated polyimide tape wrapped windings for providing a bonded, solid monolithic structure. The induction heating coil includes a cooling heatsink of predetermined size and shape fused in relationship to a plurality of consecutive turns of current-carrying coil windings. A plurality of fluoroplastic coated polyimide sheets are fused to the coil body between the coil body and a fluoroplastic face sheet forming the outer wear surface of the induction heater coil, thereby providing a non-stick surface for release of hot melt adhesives.

An induction heating coil having fluoroplastic coated polyimide tape wrapped windings for providing a bonded, solid monolithic structure. The induction heating coil includes a cooling heatsink of predetermined size and shape fused in relationship to a plurality of consecutive turns of current-carrying coil windings. A plurality of fluoroplastic coated polyimide sheets are fused to the coil body between the coil body and a fluoroplastic face sheet forming the outer wear surface of the induction heater coil, thereby providing a non-stick surface for release of hot melt adhesives.

An induction heating coil having fluoroplastic coated polyimide tape wrapped windings for providing a bonded, solid monolithic structure. The induction heating coil includes a cooling fin of predetermined length extending in interleaved relationship between a plurality of consecutive turns of current-carrying coil windings. A plurality of fluoroplastic coated polyimide sheets are fused to the coil body between the coil body and a fluoroplastic face sheet forming the outer wear surface of the induction heater coil, thereby providing a non-stick surface for release of hot melt adhesives.