Abstract: A laminated amorphous metal strip has a first layer having at least two side-by-side strips of amorphous metal of unequal widths. A second layer has at least two side-by-side strips of amorphous metal of unequal widths, the layers being in reverse order with respect to the widths of the strips such that the wider strips overlap and form a brickwork cross-section pattern. A flexible polymeric bonding material is disposed between the layers. The polymeric bonding material is an adhesive and has excellent electrical properties. A device for forming the laminated strip of amorphous metal has a plurality of rolls of amorphous metal. Strips from a roll are positioned side-by-side with strips from a wider roll. A bonding material is applied from spray guns to the surface of the strips. Strips from a roll of metal and a wide roll of metal are positioned on the bonding material in a reverse order of the wider strips. Pressure is applied to the laminate.

Abstract: A method of joining transformer winding conductor cables is disclosed. Initially, the ends of the conductor cables to be joined are cut in a staggered configuration. The staggered ends are then chamfered. The ends are then welded together to form a staggered joint which is of substantially the same thickness as the individual conductor cables.

Abstract: A method of joining transformer winding conductor cables is disclosed. The ends of the conductor cables to be joined are first chamfered to both clean and taper the respective ends. The tapered ends are then overlapped and pressed together. Vibratory energy is then applied to at least one of the overlapped ends to weld the cleaned conductor cable ends together to form a joint that has substantially the same cross sectional area as the conductor cables themselves.

Abstract: A high-voltage winding for core-form power transformers is disclosed that uses two different conductor configurations within a single coil to minimize eddy current losses. The winding includes a first elongated conductor bundle formed from a plurality of thin enamel coated conductor ribbons arranged in side by side relation. A plurality of second elongated conductor bundles are each formed from at least one bundle section having a multiplicity of elongated insulated conductor strands arranged in side by side relation. Each of the conductor strands is less than 40 mils thick. The coil includes a top end section, a body section and a bottom end section. The body section is spirally wound with the first conductor bundle. The top and bottom end sections are wound with the second conductor bundles. In windings that include tap connectors, the tap section is also wound with one of the second conductor bundles.

Abstract: A plurality of separate blanks or punchings can be continually processed by first cutting the strips into the dimensions needed for core punchings prior to thermal and magnetic annealing. Thereafter the cut punchings can be fed into the annealing line a conveyor in the sequence of one after another in series, alternatively side-by-side in parallel. The punchings will be flattened with rollers or a press during the stage of heating from room temperature to approximately 300.degree. C. The molten metals adhering to the laser-cut edges or burrs from the mechanical shear can be mechanically removed at this point by brushing. The strips may then be thermally and magnetically annealed in the soaking area. In one embodiment, the temperature may be 400.degree. C. .+-.20.degree. C. for 2605-S2 Metglas material and 360.degree. C. .+-.10.degree. C. for 2605S-C Metglas material with a field of 10 Oe in a non-oxidizing environment.

Abstract: A current transformer is encapsulated in an injection molded layer of insulating material. The current transformer includes a secondary terminal assembly having individual terminals mounted on a terminal board. The terminal board is formed of a material that softens within the normal processing temperature range of the encapsulating material and forms an amalgamation therewith without a distinct interface between the terminal board and the encapsulating material which thereby provides a fluid-tight seal around the terminal assembly. The individual terminals have an intermediate shoulder disposed adjacent the top surface of the terminal board to prevent the molding material from covering the terminal assembly during the injection molding operation and, further, to provide a sealing surface for the molding material around the terminal assembly. A shorting bar is rotatably mounted between the terminals and rotates between a closed position shorting the terminals and an open non-shorting position.

Abstract: A one-piece insulated bus bar adaptor is removably attachable by spaced attachment sides having recesses for receiving retainer projections extending from the opposite end walls of a window type current transformer so that the adaptor is attached in a predetermined indexed position within the transformer opening with a bar mounting slot thereof having a predetermined fixed position for securing the current transformer.

Abstract: A current transformer is encapsulated in an injection molded layer of insulating material. The current transformer includes a secondary terminal assembly having individual terminals mounted on a terminal board. The terminal board is formed of a material that softens within the normal processing temperature range of the encapsulating material and forms an amalgamation therewith without a distinct interface between the terminal board and the encapsulating material which thereby provides a fluid-tight seal around the terminal assembly. The individual terminals have an intermediate shoulder disposed adjacent the top surface of the terminal board to prevent the molding material from covering the terminal assembly during the injection molding operation and, further, to provide a sealing surface for the molding material around the terminal assembly. A shorting bar is rotatably mounted between the terminals and rotates between a closed position shorting the terminals and an open non-shorting position.

Abstract: A current transformer encapsulated in an injection molded layer of insulating material. The current transformer includes a secondary winding which is disposed around a winding spool having side flanges thereon. Permanent spacers extend across the length of the winding spool and rest on the side flanges such that the permanent spacers are spaced from the secondary winding. A primary winding is wound around the spacers so as to be spaced from the secondary winding before the encapsulating material is injection molded around the magnetic core and windings and into the space between the primary and secondary windings. The winding spool and permanent spacers are formed of a material which softens within the processing temperature range of the encapsulating material to form an amalgamation without a distinct interface between the encapsulating material and the winding spool and spacers.

Abstract: A cast bushing having a capacitor structure which includes concentrically positioned capacitor sections. Each capacitor section includes a spacing member which helps to maintain the distance between the conducting portions of the capacitor sections during the casting process. The spacing members consist of a tapered cylindrical non-conductive mesh around which another mesh member and a conductive foil are positioned. The diameter of the smaller opening of the tapered mesh permits the insertion of a similarly constructed but smaller diameter capacitor section inside the tapered mesh to form concentric capacitor sections. The rigidity of the tapered portion of the mesh maintains the desired distance between the conducting foils of the two concentric capacitor sections. Two-piece mandrel assemblies are used to construct each capacitor section.