METHOD OF MAKING ELECTRICAL TRANSFORMER MEANS
First Claim
1. A method of making an improved electrical transformer comprising the steps of, providing metal core means having expOsed outer surface means at opposite ends of said core means, providing electrical coil meany having a plurality of winding layers adapted to be supported exteriorly of said exposed outer surface means, forming slot means between a pair of adjoining layers of said plurality of layers, said slot means extending across the full height of said coil means, supporting said coil means within said metal core means with said slot means arranged exteriorly of said exposed outer surface means, providing metal heat transfer means, and placing said metal heat transfer means within said slot means, whereby said metal heat transfer means extends outwardly from said slot means and transfers heat from within said assembled transformer to the exterior thereof to provide an improved more efficient transformer.
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Abstract
This disclosure relates to improved electrical transformer means which has heat transfer surface means for transferring heat outwardly from within electrical coil means of such transformer means to thereby provide optimum electrical performance and to an improved method of making such transformer means and associated coil means.
34 Citations
10 Claims
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1. A method of making an improved electrical transformer comprising the steps of, providing metal core means having expOsed outer surface means at opposite ends of said core means, providing electrical coil meany having a plurality of winding layers adapted to be supported exteriorly of said exposed outer surface means, forming slot means between a pair of adjoining layers of said plurality of layers, said slot means extending across the full height of said coil means, supporting said coil means within said metal core means with said slot means arranged exteriorly of said exposed outer surface means, providing metal heat transfer means, and placing said metal heat transfer means within said slot means, whereby said metal heat transfer means extends outwardly from said slot means and transfers heat from within said assembled transformer to the exterior thereof to provide an improved more efficient transformer.
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2. The method as set forth in claim 1 in which said step of providing metal heat transfer means comprises providing metal strips and said placing step comprises extending said metal straps from opposite ends of said slot means beyond associated opposite ends of said coil means.
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3. The method as set forth in claim 2 in which said step of forming slot means comprises forming substantially rectangular passage means in said coil means which extends completely across said coil means between said pair of adjoining layers and said placing step comprises extending said elongated metal strips beyond opposite ends of said rectangular passage means and hence beyond associated opposite ends of said coil means.
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4. The method as set forth in claim 3 in which said step of providing elongated strips comprises providing a single elongated flat metal strip, said placing step comprises inserting said elongated metal strip so that it extends completely through said rectangular passage means and exteriorly of opposite coil ends thereof, and comprising the further step of shaping both opposite strip ends thereof so they lie adjacent said outer surface means.
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5. The method as set forth in claim 4 in which, said step of providing a single elongated flat metal strip comprises providing an elongated strip which is more than twice the length of said rectangular passage means, said shaping step comprises shaping the opposite ends thereof so each extends in an arcuate path, and comprising the further step of fastening said ends together to define a tubular substantially D-shaped metal heat transfer means.
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6. The method as set forth in claim 5 comprising the further steps of, providing cover means adapted to enclose said plurality of layers, fastening said cover means against said exposed outer surface means to enclose said metal plurality of layers, and fastening said strip ends against said cover means during said shaping step.
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7. The method as set forth in claim 3 in which said step of providing metal strips comprises providing a pair of metal strips and said placing step comprises inserting each of said metal strips from opposite ends of said rectangular passage means so that they abut each other adjacent the center portion of said passage means.
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8. The method as set forth in claim 7 comprising the further step of, shaping each of said pair of metal strips prior to inserting each of said strips in position during said placing step so as to define a substantially Z-shaped metal heat transfer means, and said placing step further comprises placing a portion of each of said strips adjacent said outer surface means.
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9. The method as set forth in claim 7 further comprising the steps of, providing guide means adapted to hold said pair of metal strips in position, supporting said means within said rectangular passage means, and said placing step comprises inserting each of said strips from opposite ends of said rectangular passage means into said guide means.
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10. The method as set forth in claim 1 in which said placing step further comprises arranging said metal strips immediately adjacent said outer surface means, and comprising the further steps of providing cover means adapted to be fastened against said outer surface means and fastening said cover means against said outer surface means with said metal strips having its opposite ends arranged between said cover means and said outer surface means.
Specification