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 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 fabricated in two semitoroidal sections which together form an arcuate elongated passage therethrough. Two bobbin halves are inserted into the semitoroidal sections of the low and high voltage coils and are joined to form a cylindrical bobbin within the arcuate elongated passage. The preferred annular magnetic core is wound onto the bobbin within the 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.

Abstract: A toroidal transformer insulation tube includes first and second identical, molded plastic U-channel halves. The halves each have an arcuate bottom and generally semi-cylindrical sides which extend upwardly from the bottom and terminate in inner and outer edges. The edges have symmetrically arranged alternating lapped sections, radially offset from adjacent lapped sections, so that when one U-channel half is mounted to another U-channel half with their edges aligned, the lapped sections overlap to restrict relative radial and rotary motion between the U-channel halves. Thickened flanges are formed at the ends of the halves for strength and for keeping the electrical windings on the insulation tube. The flanges have lead slots, facing in opposite axial directions, formed therein for receipt of transformer leads so that the leads in opposed slots of opposed tubes are spaced apart.

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.