Core and winding assembly with relieved core edges and method of manufacture thereof

Claim 1

A transformer core and winding assembly comprising: A. a generally rectangular magnetic core including a pair of opposed, essentially straight winding legs of generally rectangular cross-section interconnected by a pair of opposed yokes to provide a closed magnetic circuit and to define a core window, each winding leg having an inner surface bordering said core window, an outer surface generally parallel to said inner surface, and two lateral surfaces disposed transversely of said inner surface; said inner surface being generally disposed in a first plane, said outer surface in a second plane, and said lateral surfaces in third and fourth planes that intersect said first plan in a pair of inner edge regions and intersect said second plane in a pair of outer edge regions, at least one of said winding legs being corner-relieved in said two inner edge regions and in said two outer edge regions; and B. a coil having a generally rectangular opening corresponding in cross-sectional shape to the cross-sectional shape of said one winding leg, said coil being disposed about said one leg with the corners of said coil opening accommodated in intimate, essentially conforming relationship with said one winding leg at said corner-relieved edge regions.