Abstract: The invention concerns a treatment method which consists in coating at least one surface of a brittle thin metal strip (1) with a coating film (3, 3?) comprising at least a polymer material, to obtain on the strip an adhering coat with a thickness ranging between 1 and 100 ?m, modifying the working and breaking properties of the brittle thin metal strip (1); then carrying out a step wherein the brittle thin metal strip (1) is subjected to stresses, such as a cutting operation, on the brittle thin metal strip (1) coated with the film coating (3, 3?). The method is particularly useful for producing magnetic parts from strips or ribbons with nanocrystalline structure.

Abstract: Laminated primary winding for matrix transformers may be assembled from stacked layers of metal foil or stampings having ends of the metal foil or stampings extended successively to make stepped contact areas having as large a contact area as necessary for the application. In some embodiments the stepped contact areas are on ends of the laminated primary winding that extend beyond the matrix transformer. In other embodiments, the stepped contact areas are on complementary mating subassemblies within the transformer.

Abstract: A transformer core comprises a plurality of segments of amorphous metal strips. Each of the segments comprises at least one packet of the strips. The packet comprises a plurality of groups of cut amorphous metal strips arranged in a step-lap joint pattern. Packets thus formed can have C-shape, I-shape or straight segment-shape configurations. Assembly of the transformer is accomplished by placing at least two of the segments together. Core manufacturing is simplified and core and coil assembly time is decreased. Stresses otherwise encountered during manufacture of the core are minimized and core loss of the completed transformer is reduced. Construction and assembly of large core transformers is carried out with lower stress and higher operating efficiencies than those produced from wound core constructions.

Abstract: An electrical machine has a core that includes stranded magnetically permeable material. The core is elongated to thereby define a lengthwise direction and a profile that is transverse to the lengthwise direction. Coils are wound about the core profile and sequentially disposed along the lengthwise direction. A magnet is adjacent to the core and movable relative to the core.

Abstract: Plural magnetic sheets (22) are laminated in circumference direction to form a cylindrical laminated core. Magnetic sheets (22) adjacent to each other have coupling point (25) at an upper section or a lower section and gap (26) on an opposite side of coupling point (25). Coupling point (25) is prepared at upper section (23), then lower section (24), and upper section (23) then lower section (24) alternately. This structure allows assembling a radial laminated core with ease.

Abstract: One embodiment of the invention is an inductor that is formed on a printed circuit board comprising a core of ferromagnetic material that is formed on a layer of the printed circuit board, and a winding that surrounds a portion of the core and is formed from a plurality of vias in the printed circuit board.

Abstract: A magnetic implement has a gap size ranging from about 1 to about 20 mm. The implement comprises a magnetic core composed of an amorphous Fe-based alloy. A physical gap is disposed in the core's magnetic path. The alloy has an amorphous structure; is based on the components: (Fe—Ni—Co)—(B—Si—C). The sum of its Fe+Ni+Co content is in the range of 65–85 atom percent. Advantageously, the core exhibits an overall magnetic permeability ranging from about 40 to about 200 and enhanced magnetic performance.

Abstract: The invention, Conducting and Magnetizing Double Spiral Capacitor-inductor, consists of two insulated, conducting and at the same time, at least one of them, magnetizing spiral bands or tapes that are spooled in interleaved fashion into a spiral disk or roll and connected galvanically onto two electrodes that are placed on the opposite ends of the bands, one on each. The bands constitute a capacitor-inductor, and the electric current is always flowing in the same direction in both bands when the capacitor is charged or discharged creating a magnetic field that is perpendicular to the flat sides of the spiral disk or roll and to the electric field that lies perpendicularly between the bands. The otherwise free ends of the bands can be connected together with a fixed or adjustable resistive load to change the values of the device. This kind of combined capacitor-inductor can be used as a component in many electric apparatuses.

Abstract: A reverse-direction staple system for a plurality of members to be stacked on top of one another is provided. The system includes an upwardly extending staple, a staple access hole, and a staple clearance opening defined in each member to be stacked. The upwardly extending staple of each member extends through the staple access hole of a subsequent member and forms a bent staple over the subsequent member. In addition, the bent staples are received in the staple clearance opening of a second subsequent member.

Abstract: Non-linear inductor(s) are used to reduce the percent total harmonic distortion of the harmonics in the line currents in the input side rectifier system of an ac drive system. Several constructions for the non-linear inductor(s) are described. The non-linear inductor(s) may be constructed from E and I laminations. The gap depends on the construction of the middle leg of the E laminations and may have a step with a constant spacing or a variable spacing which depends on the stacking of the laminations. Alternatively the non-linear inductor(s) may be constructed from a toriodal core that either has a step gap or a variable type gap.

Abstract: The present invention provides a boosting transformer for microwave oven, which is low in high-frequency loss, hardly saturated, small in size and easy to produce. The boosting transformer includes a rod-like ferrite core; and primary, secondary and heater windings wound around the rod-like ferrite core and piled up side by side in a direction of an axis of the rod-like ferrite core. It also includes a metal core formed from a long metal thin plate rolled by a plurality of times into a square-ring having one inner diameter larger than each of outer sizes of the primary, secondary and heater windings and the other inner diameter larger than a total size of the three windings piled up side by side, the metal core being arranged opposite to the rod-like ferrite core through a gap so as to be fitted toward the rod-like ferrite core from the outside of the primary, secondary and heater windings.

Abstract: A pencil ignition coil assembly module (40) that has a frusto-conically tapered core (46) and encapsulation (280) surrounding the side of the core. Features (216, 230, 234) center the core to a bobbin 48. A retainer (240, 240A) captures the core within the bobbin.

Abstract: A low cost moldable transformer or trans-inductor core, referred to in this description as a transductor. Elements of the transductor core are formed of a conductive loaded resin-based material. The conductive loaded resin-based material comprises micron conductor fibers, micron conductor powders, or in combination thereof homogenized within a base resin host wherein the ratio of the weight of the conductor fibers, conductor powders, or combination thereof to the weight of the base resin host can be between about 0.20 and 0.40. The micron conductive fibers or powders, can be of stainless steel, nickel, copper, silver, carbon, graphite, plated particles, plated fibers, or the like. Transductors can be formed using methods such as injection molding, over-molding, thermo-set, protrusion, extrusion, compression, or the like, in combination with a large number of production or wire wrapping techniques to achieve desired electrical characteristics.

Abstract: Non-linear inductor(s) are used to reduce the percent total harmonic distortion of the harmonics in the line currents in the input side rectifier system of an ac drive system. Several constructions for the non-linear inductor(s) are described. The non-linear inductor(s) may be constructed from E and I laminations. The gap depends on the construction of the middle leg of the E laminations and may have a step with a constant spacing or a variable spacing which depends on the stacking of the laminations. Alternatively the non-linear inductor(s) may be constructed from a toriodal core that either has a step gap or a variable type gap.

Abstract: The present invention provides a magnetic core whose outer surface has been coated without handling brittle ribbon to thereby impart insulating properties and shape retention properties to the magnetic core after annealing heat treatment, and further provides an adhesive resin composition for a magnetic core, which is useful for efficiently producing the above-mentioned magnetic core without using any organic solvent and which per se is stable to heat and elapse of time. By forming a coating film having a certain thickness or more on an outer surface using a composition containing a resin of specific properties, there can be obtained a magnetic core whose outer surface has been coated without handling brittle ribbon to thereby impart insulating properties and shape retention properties to the magnetic core after annealing heat treatment.

Abstract: A core for a multi-phase transformer includes a body made of two or more rings having a common central axis. Each ring consists of a strip of magnetic permeable material wound about the central axis. The body is provided with a plurality of radially disposed windows, each window being bound by opposed axially extending legs and opposed circumferentially extending branches. The branches of each window are provided in respective axially adjacent rings, so that the branches and legs of each window define a closed magnetic circuit of substantially uniform magnetic permeability through which magnetic flux can circulate about the windows.

Abstract: An oscillating inductor has a symmetrical double-E core, which has two geometrically identical core windows, a cuboid center limb and two cuboid outer limbs. The double-E core is designed such that a longitudinal cross sectional area of the center limb is greater than 90 mm2, with a longitudinal cross section being regarded as a cross section which would separate the double-E core into two single E-cores, and the cross section being at right angles to the longitudinal cross section such that the double-E can be identified in the cross section, with the double-E core being located in a component volume of less than 26.5 mm×26.5 mm×15 mm (width×depth×height).

Abstract: A laminated plate assembly in which the laminations in a stack are secured together by means of one or more interlocks or tabs that project from the uppermost lamination in the assembly through holes or slots in all the other laminations in the assembly, or around the periphery of the other laminations in the assembly, with each tab being bent or pressed against the underside of the bottom lamination in the assembly. This secures all the laminations in the stack together, much like a staple secures papers in a stack together, allowing for additional handling and processing of the laminated plate assembly without concern that the laminated plates in the stack will become misaligned or even become removed from the stack.

Abstract: The invention provides an apparatus and manufacturing methods useful in the manufacture of large transformer cores, particularly, in the manufacture of large transformer cores made of a ferromagnetic material, especially of annealed amorphous metal alloys. The invention further provides transformer cores produced utilizing the inventive apparatus and manufacturing methods, as well as finished transformers which include such transformer cores.

Abstract: A method of firing magnetic cores includes the steps of attaching a powder to the surface of a plurality of flattened-ring compact bodies made of a magnetic material, arranging the plurality of flattened-ring compact bodies adjacently so that the axes of flattened through-holes of the flattened-ring compact bodies are vertically oriented, and firing the flattened-ring compact bodies while the powder is interposed between the adjacent flattened-ring compact bodies. Alternatively, a method of firing magnetic cores includes the steps of attaching a powder to the surface of a plurality of thin compact bodies made of a magnetic material, vertically arranging the plurality of thin compact bodies adjacently, and firing the thin compact bodies while the powder is interposed between the adjacent thin compact bodies.

Abstract: A silicon steel core for transformers or choke coils includes at least one silicon steel sheet core which has at least two sets of silicon steel sheets that have respectively a magnetic flux section of a different length such that when two sets of the silicon steel sheet cores are coupled, the magnetic flux sections form at least two gaps of different intervals. Thereby the silicone steel sheet sets of a smaller gap can provide adequate electric induction for the transformers or choke coils while the silicone steel sheet sets of a greater gap can reduce the saturated condition when the transformers or choke coils are in the high load condition.

Abstract: A transformer or inductor core of magnetic material has three legs (6, 8, 10) interconnected by yokes. The core comprises loops (12, 14, 16) of wires and/or strips of magnetic material, wherein each of the loops makes up part of two of the legs. Loops making up part of two different leg portions are interleaved in a common leg portion. This provides for mechanical stability and good magnetic properties for the core.

Abstract: Opposing concave structures formed in an end portion 22b of a stator yoke 22 and an end portion 23b of a magnetic core 23 are mated in a staggered manner and are joined. An upper projecting portion 22b-1 of the stator yoke 22 is fitted in a recessed portion formed on a lower projecting portion 23b-2 of the magnetic core 23, and the lower projecting portion 23b-2 of the magnetic core 23 is fitted in a recessed portion formed under the upper projecting portion 22b-1 of the stator yoke 22. In this state, the stator yoke 22 and the magnetic core 23 are fixedly fastened by a joint screw 24 and a tube 26. This structure makes it possible to reduce magnetic resistance in a magnetic circuit structure and to improve power-generating efficiency of a power-generating device using the structure.

Abstract: A laminated electronic component including at least one inductance element and produced from a laminate having electrical insulators and electrical conductors laminated alternately. The inductance element is formed as a helical coil having a plurality of turns each constituted by four sides. The inductance element has pairs of parallel conductor pieces and pairs of bridging conductor pieces. Each pair of parallel conductor pieces form two of the four sides of one turn of the coil. Each pair of bridging conductor pieces form the other two sides of one turn of the coil. Grooves are formed in the laminate to thereby form the parallel conductor pieces. The grooves are filled with an electrically insulating material. The bridging conductor pieces are formed on the electrically insulating material.

Abstract: A core lamination for electromagnetic devices, including a substantially T-shaped central member constituted by a crossbar and a post, the post having at least two notches, one on each side of its lower portion; first and second side members, each of the side members constituted by a post and a foot, each foot having a tooth-like projection at its end; wherein, for assembly, the first and second side members are placed on the left and the right, respectively, of the T-shaped central member, with the tooth-like projections engaging the respective notches on the post of the central member.

Abstract: An improved silicon steel core for transformers or choke coils includes at least one silicon steel sheet core which has at least two sets of silicon steel sheets that have respectively a magnetic flux section of a different length such that when two sets of the silicon steel sheet cores are coupled the magnetic flux sections form at least two gaps of different intervals. Thereby the silicone steel sheet sets of a smaller gap can provide adequate electric induction for the transformers or choke coils while the silicone steel sheet sets of a greater gap can reduce the saturated condition when the transformers or choke coils are in the high load condition so that the transformers or choke coils can reach a required electric induction without increasing the number of the silicon steel sheets or copper coils of the transformers or the choke coils, and prevent the transformers or choke coils from occurring saturation on the entire magnetic core in the high load.

Abstract: A highly-laminated magnetic inductor core and integrated inductor, and methods for making the same are disclosed. A representative method for manufacturing a highly-laminated magnetic inductor core includes: depositing at least a first layer of a ferromagnetic material; depositing at least a first layer of a sacrificial conductive material; depositing a support structure formed of a ferromagnetic material; and removing the sacrificial conductive material, thereby leaving the at least first layer of ferromagnetic material mechanically supported by the support structure.

Abstract: The present invention includes an element for use in an inductive coupler in a downhole component. The element includes a plurality of ductile, generally U-shaped leaves that are electrically conductive. The leaves are less than about 0.0625″thick and are separated by an electrically insulating material. These leaves are aligned so as to form a generally circular trough. The invention also includes an inductive coupler for use in downhole components, the inductive coupler including an annular housing having a recess with a magnetically conductive, electrically insulating (MCEI) element disposed in the recess. The MCEI element includes a plurality of segments where each segment further includes a plurality of ductile, generally U-shaped electrically conductive leaves. Each leaf is less than about 0.0625″thick and separated from the otherwise adjacent leaves by electrically insulating material. The segments and leaves are aligned so as to form a generally circular trough.

Abstract: The invention is to provide a method of making an amorphous laminated core having sufficient caulking strength and core shaping precision and having high precision in shaping the core and the caulking strength even if the amorphous laminated core has the minimum size for pocket telephones, and to provide such an amorphous laminated core. That is, a method of making the amorphous laminated core by punching core pieces from the amorphous thin sheet material, laminating the plural sheets of core pieces and caulking them, comprises a step of laminating the plural sheets of the core pieces having the caulking through-holes formed by punching, a step of inserting rod shaped materials into the caulking through-holes of the laminated core pieces, and a step of pushing back the inserted rod materials, thereby to caulk the core pieces of the plurality of laminated sheets. Further, in the amorphous laminated core, non-magnetic rod shaped materials are put in the caulking through-holes.

Abstract: Non-linear inductor(s) are used to reduce the percent total harmonic distortion of the harmonics in the line currents in the input side rectifier system of an ac drive system. Several constructions for the non-linear inductor(s) are described. The non-linear inductor(s) may be constructed from E and I laminations. The gap depends on the construction of the middle leg of the E laminations and may have a step with a constant spacing or a variable spacing which depends on the stacking of the laminations. Alternatively the non-linear inductor(s) may be constructed from a toriodal core that either has a step gap or a variable type gap.

Abstract: To provide a technology capable of restraining direct current magnetic deviation in a transformer without providing a gap in a core, an axis of easy magnetization is provided in a second direction intersecting with a first direction along a magnetic circuit of the core to thereby bring a B-H characteristic of a material characteristic of the core into an unsaturated state.

Abstract: Transformer cores, especially those of wound or laminated annealed amorphous metals which include support assemblies are disclosed. Methods for their manufacture, and their use in assembled transformers are also disclosed.

Abstract: A high performance bulk magnetic component includes a plurality of layers of crystalline, ferromagnetic metal strips adhesively bonded together to form a polyhedrally shaped part. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it exhibits a core-loss less than “L” wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively. Performance characteristics of the high performance bulk magnetic component of the present invention are significantly better when compared to silicon-steel components operated over the same frequency range.

Abstract: A bulk amorphous metal inductive device comprises a magnetic core having plurality of low-loss bulk ferromagnetic amorphous metal magnetic components assembled in juxtaposed relationship to form at least one magnetic circuit and secured in position, e.g. by banding or potting. The device has one or more electrical windings and may be used as a transformer or inductor in an electronic circuit. Each component comprises a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhedrally shaped part. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful for application in power conditioning circuits operating in switched mode at frequencies of 1 kHz or more. Air gaps are optionally interposed between the mating faces of the constituent components of the device to enhance its energy storage capacity for inductor applications.

Abstract: An electrical conductor winding (70) comprises a plurality of laminates of electrical insulation (72). Each laminate of electrical insulation (72) has a slot (78) on one surface (76). Each laminate of electrical insulation (70) has an electrical conductor (82) arranged in the slot (78). An electrical connector (84) connects the electrical conductor (82) in one laminate of electrical insulation (78) with the electrical conductor (82) in an adjacent laminate of electrical insulation (72). The laminates of electrical insulation (72) are arranged such that the surface (74) of one laminate of electrical insulation (72) abuts and is bonded to the surface (76) of an adjacent laminate of electrical insulation (12). The laminates of electrical insulation (12) comprise a glass-ceramic material. The electrical conductor windings allow active magnetic bearings, electric motors and electric generators to be used at temperatures up to 500° C. for example in gas turbine engines.

Abstract: An on-chip signal transforming device includes a substrate and a first conductive layer above the substrate, wherein the first conductive layer has a plurality of interleaved inductors. The device further includes a second conductive layer above the substrate, wherein the second conductive layer has at least one inductor.

Abstract: Non-linear inductor(s) are used to reduce the percent total harmonic distortion of the harmonics in the line currents in the input side rectifier system of an ac drive system. Several constructions for the non-linear inductor(s) are described. The non-linear inductor(s) may be constructed from E and I laminations. The gap depends on the construction of the middle leg of the E laminations and may have a step with a constant spacing or a variable spacing which depends on the stacking of the laminations. Alternatively the non-linear inductor(s) may be constructed from a toriodal core that either has a step gap or a variable type gap.

Abstract: Non-linear inductor(s) are used to reduce the percent total harmonic distortion of the harmonics in the line currents in the input side rectifier system of an ac drive system. Several constructions for the non-linear inductor(s) are described. The non-linear inductor(s) may be constructed from E and I laminations. The gap depends on the construction of the middle leg of the E laminations and may have a step with a constant spacing or a variable spacing which depends on the stacking of the laminations. Alternatively the non-linear inductor(s) may be constructed from a toriodal core that either has a step gap or a variable type gap.

Abstract: A transformer includes a ferrite base plate having ferrite core between two grooves, two or more windings wound around the ferrite core and engaged in the grooves of the ferrite base plate and electrically coupled together and separated from each other, for forming two spaces in the grooves of the ferrite base plate and formed between the windings. One or more conductive panels may be engaged into each of the spaces of the ferrite base plate for reducing the voltage generated by the windings, and for supplying a stabilized electric power source to electric devices.

Abstract: A noise filter includes a plurality of magnetic sheets stacked one on another. The magnetic sheets are baked to form a layered product. A transmission line is arranged between the second and third magnetic sheets. The transmission line extends linearly in the longitudinal direction of the layered product. Two ground conductors have the second and third magnetic sheets therebetween. Signal electrodes connected to both ends of the transmission line are arranged adjacent to both ends, in the longitudinal direction, of the layered product. Grounding electrodes connected to the ground conductors are arranged in the middle positions, in the longitudinal direction, of the layered product. With the ground conductors being grounded, a signal passes through the transmission line, thus attenuating high-frequency noise using heat dissipation by the four magnetic sheets.

Abstract: A first core is formed by stacking a plurality of magnetic plates of a soft magnetic material, such as iron, in a direction perpendicular to a plane of each magnetic plate. A bonding thin layer made of iron oxide having a thickness of approximately a few nanometers to a few hundred micrometers is formed between adjacent ones of the magnetic plates. The adjacent magnetic plates are bonded to each other by diffusion bonding in such a manner that the bonding thin layer is interposed between the adjacent magnetic plates to electrically insulate between the adjacent magnetic plate.

Abstract: An ignition coil for an internal combustion engine is mainly made up of a transformer part and a control circuit part and a connecting part, and the transformer part is made up of a iron core which forms an open magnetic path, magnets, a secondary spool, a secondary coil, a primary spool and a primary coil. By respectively setting the cross-sectional area SC of the iron core between 39 to 54 mm2, the ratio of the cross-sectional area SM of the magnets with the cross-sectional area SC of the iron core in the 0.7 to 1.4 range, the ratio of the axial direction length LC of the iron core with the winding width L of the primary and secondary coils in the 0.9 to 1.2 range, and the winding width L in the 50 to 90 mm range, the primary energy produced in the primary coil can be increased without increasing the external diameter A of the case.

Abstract: A pencil ignition coil assembly module (40) that has a frusto-conically tapered core (46) and encapsulation (280) surrounding the side of the core. Features (216, 230, 234) center the core to a bobbin 48. A retainer (240, 240A) captures the core within the bobbin.

Abstract: A core has a plurality of plate-shape core pieces with a magnetic pole tooth and having connecting portions formed at one end and having a first circular arc end surface and having at the other end a second end surface which can mate with the first end surface of an adjoining core piece. The core pieces are arranged in the shape of a strip through the end surfaces to form a first core member and a second core member. The core members are stacked so that the ends of adjoining core pieces in the stacking direction overlap and such that adjoining connecting portions can freely rotate through connecting means to form a ring with the magnetic pole teeth on the inside. A cutout is formed in the corner of the outer side of the core in the second end surface of each core piece.

Abstract: An inductance arrangement is directed to inductors, chokes and transformers with a very high power density. Chokes comprise a magnetic circuit and an electrical circuit, the latter usually comprising a copper winding. The inductance arrangement improves cooling of the magnetic circuit, efficiency of the induction arrangement, and reduces the consumption of material for the windings for a lower weight and a reduced structural size. Individual plate packs in the induction arrangement are displaced relative to each other to increase the surface area at both sides of the iron core. Displacement of the plates of the limbs allows for effective cooling passages or ducts between the core and the surrounding winding.

Abstract: A transformer includes a ferrite base plate having a chamber for receiving a winding and one or more further windings which may be coupled to a ground. The windings are electrically coupled together, and separated from each other by partitions. An insulating strap may be wound around the ferrite base plate, and engaged with the ground, for securing the ground to the ferrite base plate and for preventing the ground to the ferrite base plate from moving relative to the ferrite base plate. One or more conductive panels may be engaged between the partitions of the windings.

Abstract: Disclosed herein is a planar magnetic element comprising a substrate, a first magnetic layer arranged over the substrate, a first insulation layer arranged over the first magnetic layer, a planer coil formed of a conductor, having a plurality of turns, arranged over the first insulation layer and having a gap aspect ratio of at least 1, the gap aspect ratio being the ratio of the thickness of the conductor to the gap between any adjacent two of the turns, a second insulation layer arranged over the planar coil, and a second magnetic layer arranged over the second insulation layer. When used as an inductor, the planar magnetic element has a great quality coefficient Q. When used as a transformer, it has a large gain and a high voltage ratio. Since the element is small and thin, it is suitable for use in an integrated circuit, and can greatly contribute to miniaturization of electronic devices.

Abstract: The invention provides an apparatus and manufacturing methods useful in the manufacture of large transformer cores, particularly, in the manufacture of large transformer cores made of a ferromagnetic material, especially of annealed amorphous metal alloys. The invention further provides transformer cores produced utilizing the inventive apparatus and manufacturing methods, as well as finished transformers which include such transformer cores.

Abstract: An inductor with multiple air-gap separations comprises a magnetic core and an enameled wire around the magnetic core. The magnetic core has an air gap with at least a large-gap portion and a small-gap portion. The small-gap portion provides enough inductance in case of low load input to prevent harmonic distortion. The large-gap portion provides enough inductance in case of heavy load output and low input voltage to prevent saturation and temperature rise, thus enhancing power efficiency.

Abstract: Apparatus and manufacturing methods are provided which are useful in the manufacture of large transformer cores, particularly, in the manufacture of large transformer cores made of a ferromagnetic material, especially of annealed amorphous metal alloys. Further provided are transformer cores produced utilizing the disclosed apparatus and manufacturing methods, as well as finished transformers which include such transformer cores.