Abstract: A method of making a repairable transformer having an amorphous metal core. The three uncut legs of an annealed wound amorphous metal core are covered with an adhesive material while leaving the cut leg and both adjoining radii covered, but not bonded. The core joint is opened and coils are placed over the legs that adjoin the cut leg. The core joint is closed and the edges of the joint and both adjoining radii are covered with an inner layer of porous material which is secured by an outer wrap of electrical grade steel. The resulting transformer can be easily repaired by unwrapping away the porous material that covers the cut leg and the adjoining radii, opening the core joint, replacing a defective coil or core, reclosing the core joint, and rewrapping the porous material and reclosing the outer layer of electrical grade steel.

Abstract: Disclosed is a method of making a repairable transformer having an amorphous metal core. The three uncut legs of an annealed wound amorphous metal core are covered with an adhesive material while leaving the cut leg and both adjoining radii covered, but not bonded. The core joint is opened and coils are placed over the legs that adjoin the cut leg. The core joint is closed and the edges of the joint and both adjoining radii are covered with an inner layer of porous material which is secured by an outer wrap of electrical grade steel. The resulting transformer can be easily repaired by unwrapping away the porous material that covers the cut leg and the adjoining radii, opening the core joint, replacing a defective coil or core, reclosing the core joint, and rewrapping the porous material and reclosing the outer layer of electrical grade steel.

Abstract: Disclosed is a method of making a repairable transformer having an amorphous metal core. The three uncut legs of an annealed wound amorphous metal core are covered with an adhesive material while leaving the cut leg and both adjoining radii covered, but not bonded. The core joint is opened and coils are placed over the legs that adjoin the cut leg. The core joint is closed and the edges of the joint and both adjoining radii are covered with an inner layer of porous material which is secured by an outer wrap of electrical grade steel. The resulting transformer can be easily repaired by unwrapping away the porous material that covers the cut leg and the adjoining radii, opening the core joint, replacing a defective coil or core, reclosing the core joint, and rewrapping the porous material and reclosing the outer layer of electrical grade steel.

Abstract: A method of making a transformer having an amorphous metal core uses resin coated substrate to reduce amorphous metal contaminants in the transformer coolant. The face of an annealed wound amorphous metal core is covered with a resin coated substrate. The core and resin coated substrate are bonded by pressing the core face. The second face is then done in the same way. The resulting resin coated substrate and transformer core is a unit. The substrate prevents amorphous metal pieces from escaping into the transformer oil and becomes a structural member of the core.

Abstract: A method of constructing a jointed magnetic core from amorphous metal, which includes winding a closed core loop having a plurality of nested lamination turns disposed about a core opening or window, and positioning the closed core loop on a support surface with the winding axis horizontally disposed, to allow the inherent flexibility of amorphous metal to collapse the loop opening and create a concave loop in the unsupported portion of the closed core loop. The method further includes the step of lifting a plurality of lamination turns from the concave loop portion, to provide a clearance between the raised lamination turns and the remaining lamination turns in the concave loop to facilitate cutting the lamination turns. A cutting device, which may be a laser or a mechanical cutter, cuts one or more of the raised lamination turns.