Energy saving wound core transformer

Claim 2

A magnetic core for a transformer, comprising: (a) a first strip of magnetic material shaped in a substantially closed loop of one turn so as to define an interior surface and an exterior surface and two abutting ends; (b) a second strip of magnetic material, generally equal in length to said first strip and wrapped about the exterior surface of said first strip, defining two abutting ends which are laterally offset from the abutting ends of the first strip; and (c) a third strip of magnetic material, interleafed between said first strip and said second strip, defining two ends which are substantially spaced apart from one another with the abutting ends of said first strip and the abutting ends of said second strip disposed intermediate the ends of said third strip, said third strip having a length such that the transverse thickness of the side of the core thereformed which is opposite the ends of said first strip and said second strip is thinner than the remaining three sides.

Claim 3

The magnetic core set forth in claim 1, wherein said first strip and said second strip are each bent at four points intermediate their abutting ends so as to form a generally closed rectangular hollow structure defining four sides, the transverse thickness of which are generally equal with one of said sides having the abutting ends of said first strip and said second strip, and wherein said third strip is bent at two points intermediate its ends so as to form a generally U-shaped strip defining three legs which are proportional in length to three of the four sides defined by said first strip and said second strip with that leg intermediate the ends of said third strip being disposed adjacent said one side of the closed rectangular hollow structure formed by said first strip and said second strip, whereby a generally rectangular magnetic core is formed with a side having a thickness less than that of the remaining three sides.

Claim 4

The magnetic core set forth in claim 1, wherein said third strip is shorter than said first strip and said second strip.

Claim 5

The magnetic core set forth in claim 1, wherein said third strip is longer than said first strip and said second strip.

Claim 6

A laminated transformer core, comprising: (a) a filler-core formed from at least one strip of magnetic material, defining an inner surface and an outer surface and two ends which are substantially separated from each other, which is wrapped about itself so that said inner surface and said outer surface substantially overlap one another, whereby an overlapped portion is defined which has an overall thickness greater than the remaining portion of said one strip and one of said two ends is disposed along said inner surface and the other of said two ends is disposed along said outer surface; (b) an inner strip of magnetic material, which is generally shorter in length relative to said one strip and which defines two ends, disposed at the inner surface of said one strip with both of the ends of said inner strip lying adjacent one another and with one of the ends of said inner strip abutting said one end of said one strip; and (c) an outer strip of magnetic material, which is generally shorter in length relative to said one strip and which defines two ends, disposed at the outer surface of said one strip with both of the ends of said outer strip lying abutting one another and with one of the ends of said outer strip adjacent said other end of said one strip.

Claim 7

A laminated transformer core, comprising: (a) a filler-core formed from at least one strip of magnetic material, defining an inner surface and an outer surface and two ends which are substantially separated from each other, which is wrapped about itself so that said inner surface and said outer surface substantially overlap one another, whereby an overlapped portion is defined which has an overall thickness greater than the remaining portion of said one strip and one of said two ends is disposed along said inner surface and the other of said two ends is disposed along said outer surface; (b) an inner strip of magnetic material, which is generally shorter in length relative to said one strip and which defines two ends, disposed at the inner surface of said one strip with both of the ends of said inner strip lying adjacent one another and with one of the ends of said inner strip abutting said one end of said one strip; and (c) an outer strip of magnetic material, which is generally shorter in length relative to said one strip and which defines two ends, disposed at the outer surface of said one strip with both of the ends of said outer strip lying abutting one another and with one of the ends of said outer strip adjacent said other end of said one strip.

Claim 8

The laminated transformer core set forth in claim 5, wherein said filler-core is formed from a first strip and a second strip of magnetic material, each of said first and second strips being generally equal in length and defining two ends, said second strip being wrapped about said first strip with one of its ends disposed adjacent and laterally separated from one end of said second strip and with the other end of said first strip disposed opposite the other end of said second strip, one of said one ends of said first strip and said second strip being disposed adjacent said one end of said outer strip and the remaining of said one ends being disposed adjacent said one end of said inner strip, whereby a wound core is formed of non-uniform cross-sectional area, with that portion of said wound core which is opposite said one end of said first strip being generally thinner than that portion of said wound core which is adjacent said one end of said first strip or that portion opposite to or adjacent said other end of said first strip.