Abstract: In one embodiment of the present invention, a transformer includes a first secondary winding made of stamped and bent metal. This first secondary winding has a coil portion with substantially closed cross section. The transformer also includes a primary winding made of wire and having a coil portion wound around the coil portion of the first secondary winding. A second secondary winding made of stamped and bent metal and having a coil portion with substantially closed cross section has its coil portion disposed about the coil portion of the primary winding. The primary winding further includes a second coil portion wound around the coil portion of the second secondary winding. The transformer thus provided is easier to build and less apt to internal short-circuiting than alternative designs.

Abstract: A method of assembling an electromagnetic device having a plurality of magnetic cores with substantially planar bases, by placing the magnetic cores upon a fixture adapted to align the planar bases of the magnetic cores in a coplanar relationship, applying a resilient adhesive along a core receiving side of a bracket, placing the bracket over the magnetic cores, pressing the bracket down upon the cores until the bracket's coplanar feet contact the fixture, removing the bracket and cores from the fixture, affixing a thermally conductive elastomeric pad along the coplanar bases of the magnetic cores, and fastening the coplanar feet to a thermally conductive plate so as to uniformly compress the elastomeric pad between the cold plate and the coplanar bases of the magnetic cores thereby providing a thermally efficient and shock resistant support mechanism.