Abstract: A winding apparatus for fabricating a multifilar low voltage winding for a toroidal transformer is disclosed. The apparatus uses a wire storage magazine 18 and a wire winding shuttle 20 which rotate about a semitoroidal winding mandrel 38 to wind a multifilar low voltage winding 48 on the winding mandrel having a greater radial depth of turns at the radially inward leg of the winding than at the radially outward leg of the winding. The multifilar winding can be wound with a group of conductors in a single pass over the winding mandrel, or wound one conductor at a time using multiple passes over the winding mandrel, or wound using multiple passes over the winding mandrel with some intermediate number of conductors being wound during each pass.

Abstract: The invention is directed to a formed metal blocking, for mounting within wedge-shaped gaps between coils of a toroidal transformer, including butterfly-shaped top and bottom core blockings. The blockings are formed from identical stampings, each stamping having a pair of U-shaped coil-engaging faces joined along their inner legs by a center web. The stampings are joined back to back and have a number of flanges which are bent over for securing the stampings to one another. The stampings have an apertured tab at the end of the center web used to form a lifting eye for the top blocking. With the bottom blocking, the tabs are folded over for mounting to a base plate. The outer legs of the U-shaped faces are longer than the inner legs and center web to create a gap in the electric path surrounding the core.

Abstract: The invention is directed to a formed metal blocking, for mounting within wedge-shaped gaps between coils of a toroidal transformer, including butterfly-shaped top and bottom core blockings. The blockings are formed from identical stampings, each stamping having a pair of U-shaped coil-engaging faces joined along their inner legs by a center web. The stampings are joined back to back and have a number of flanges which are bent over for securing the stampings to one another. The stampings have an apertured tab at the end of the center web used to form a lifting eye for the top blocking. With the bottom blocking the tabs are folded over for mounting to a base plate. The outer legs of the U-shaped faces are longer than the inner legs and center web to create a gap in the electric path surrounding the core.

Abstract: A winding apparatus and method for fabricating a multifilar low voltage winding for a toroidal transformer is disclosed. The method and apparatus use a wire storage magazine (18) and a wire winding shuttle (20) which rotate about a semitoroidal winding mandrel (38) to wind a multifilar low voltage winding (48) on the winding mandrel having a greater radial depth of turns at the radially inward leg of the winding than at the radially outward leg of the winding. The multifilar winding can be wound with a group of conductors in a single pass over the winding mandrel, or wound one conductor at a time using multiple passes over the winding mandrel, or wound using multiple passes over the winding mandrel with some intermediate number of conductors being wound during each pass.

Abstract: A toroidal electrical transformer having a low voltage coil, a high voltage coil and an annular magnetic core is disclosed. The preferred low voltage and high voltage coils are each continuous and form an arcuate elongated passage therethrough. The preferred annular magnetic core is wound in place in said arcuate elongated passage substantially from a continuous strip of magnetic material resulting in a toroidal transformer with cotinuous windings and a continuous wound core. Various components and sub-assemblies are also disclosed along with various apparatus and methods for producing such toroidal electrical transformers, its components and its sub-assemblies.

Abstract: A toroidal electrical transformer having a low voltage coil, a high voltage coil and an annular magnetic core is disclosed. The preferred low voltage and high voltage coils are each continuous and form an arcuate elongated passage therethrough. The preferred annular magnetic core is wound in place in said arcuate elongated passage substantially from a continuous strip of magnetic material resulting in a toroidal transformer with continuous windings and a continuous wound core. Various components and sub-assemblies are also disclosed along with various apparatus and methods for producing such toroidal electrical transformers, its components and its sub-assemblies.