Abstract: A distribution transformer (58) is assembled using a core (18) having a core surface (36) including an inner circumferential surface (40) defining an open eye region (38), an outer circumferential surface (42), and end surfaces (24, 26). Wedged-shaped core supports (20, 22), secured to the end surfaces of the core, are used to support the core during conductor winding operations and to mount the finished transformer within a transformer container (66). The core supports do not extend into the open eye region and allow virtually the entire inner circumferential surface to be covered by the electrical conductors (34, 56). The layers of electrical conductors are wound on top of one another so that each successive layer of electrical conductors conforms to the core surface and any previously wound conductors. Electrical insulation (54) is provided between each conductor layer.

Abstract: Core support blockings (10, 12) used to support a toroidal transformer (2) within a transformer housing (4) includes a pie-shaped body (28) having a second end (32) secured to the transformer core (14) using an adhesive (41). The body has adhesive flow regions, typically countersunk holes (42) passing through mounting flanges (38, 40) extending laterally adjacent the second end of the body. Electrical windings (26) can be wound on first end of the mounting flanges so to help mechanically secure the body to the core. A mounting stud (46), or other mounting element, is used to secure the transformer to a support bracket (8). Together the support bracket and core support blockings are used to support the transformer within the transformer housing.

Abstract: A finished transformer core (48) includes a core (2) of wound amorphous transformer core material (4) to which rigidifying bonding material (22) is applied to the ends (12, 14) of the core. The bonding material does not cover the entire ends but leaves gaps (24) to permit fluid flow between the ambient environment and the interlamination voids (16) which exist between the layers (18, 20) of the wound material. The core, rigidified by the bonding material, is housed within a fluid permeable containment assembly (28). The containment assembly typically includes fluid permeable filter material (32, 34, 36, 38) which allows transformer oil and air to pass through the material but will trap solid particles of core material within the containment assembly.