Abstract: A method of forming a transformer coil, wherein first and second fibrous layers are provided. Each of the first and second fibrous layers includes a fabric formed from a plurality of interconnected fibers and a plurality of spacers affixed to the fabric and protruding therefrom. A conductor layer is disposed over the first fibrous layer such that a first side of the conductor layer contacts the spacers of the first fibrous layer. The second fibrous layer is disposed over the conductor layer such that a second side of the conductor layer contacts the spacers of the second fibrous layer. A resin is applied so as to cover the conductor layer and the first and second fibrous layers.

Abstract: A transformer coil assembly includes a first layer having a plurality of fibers interconnected to form a fabric and a plurality of spacers. Each spacer is affixed on a first side of the spacer to the fabric and protruding from a first surface of the fabric. A second layer has a conductor in contact with at least one of the plurality of spacers on a second side of each spacer that opposes the first side. The first and second layers are covered by resin.