Disc-wound transformer with foil conductor and method of manufacturing the same

1. A method of manufacturing a distribution transformer comprising:

(a.) providing a core with a leg;

(b.) providing a low voltage coil;

(c.) forming a disc-wound high voltage coil comprising:

providing an insulation spool comprised of an insulating material;

providing an insulation strip;

providing a conductor strip having a width to thickness ratio of greater than about 20:1;

winding the insulation strip around the insulation spool;

winding the conductor strip around the insulation spool; and

wherein the winding of the insulation strip and the winding of the conductor strip are performed so as to form a plurality of disc windings arranged in an axial direction of the high voltage coil, and wherein each of the disc windings comprises alternating concentric layers of the conductor strip and the insulating strip;

(d.) mounting the low voltage coil to the core; and

(e.) mounting the high voltage coil to the core such that the leg extends through the insulation spool.

2. The method of claim 1 , wherein the step of providing the insulation spool is performed such that the insulation spool is comprised of fiber-reinforced plastic.

3. The method of claim 2 , wherein the step of providing the insulation spool is performed such that the insulation spool defines a first series of aligned notches and a second series of aligned notches, and wherein the step of winding the insulation strip and the conductor strip is performed such that a first disc winding is disposed in the first series of aligned notches and a second disc winding is disposed in the second series of aligned notches.

4. The method of claim 3 , wherein the step of providing the insulation spool is performed such that the insulation spool comprises:

a cylindrical insulation barrier;

a plurality of spaced-apart guide strips disposed around the circumference of the insulation barrier, each of the guide strips comprising a plurality of teeth defining first and second notches; and

wherein the first series of aligned notches comprise the first notches of the guide strips, and the second series of aligned notches comprise the second notches.

5. The method of claim 4 , wherein the step of providing the insulation spool comprises:

providing the guide strips separate from the insulation barrier; and

securing the guide strips to the insulation barrier.

6. The method of claim 4 , wherein the insulation strip has a width greater than a width of the conductor strip such that in each of the disc windings, insulation areas comprised of the insulation strip are formed between each layer of the conductor strip and the teeth of the insulation spool.

7. The method of claim 4 , wherein the forming of the disc-wound high voltage coil further comprises coating the disc windings and the insulation spool with a liquid resin while the disc windings and the insulation spool are placed under a vacuum.

8. The method of claim 3 , wherein the step of winding the conductor strip comprises performing first and second windings of the conductor strip around the insulation spool, and wherein the step of winding the insulation strip comprises performing first and second windings of the insulation strip around the insulation spool, wherein the first windings of the conductor strip and the insulation strip form the first disc winding, and the second windings of the conductor strip and the insulation strip form the second disc winding, and wherein the forming of the disc-wound coil further comprises cutting or folding the conductor strip between the first and second windings of the conductor strip.

9. The method of claim 8 , wherein between the first and second windings of the conductor strip, the conductor strip is folded to form an offset.

10. The method of claim 8 , wherein between the first and second windings of the conductor strip, the conductor strip is cut, and wherein the forming of the disc-wound coil further comprises reconnecting a portion of the conductor strip forming the first disc winding with a portion of the conductor strip forming the second disc winding.

11. The method of claim 1 , wherein the step of winding the insulation strip and the step of winding the conductor strip are performed simultaneously.

12. The method of claim 11 , wherein the step of forming the disc-wound high voltage coil further comprises unwinding the insulation strip from a roll of the insulation strip, and unwinding the conductor strip from a roll of the conductor strip.

13. The method of claim 12 , wherein the steps of winding the insulation strip and the conductor strip around the insulation spool and the steps of unwinding the insulation strip and the conductor strip from the rolls of the insulation strip and the conductor strip respectively, comprises rotating the insulation spool in a direction away from the rolls of the insulation strip and the conductor strip.

14. The method of claim 1 , wherein the conductor strip is composed of copper and has a width to thickness ratio of from about 250:1 to about 25:1.

15. The method of claim 1 , wherein the forming of the high voltage coil is performed such that the disc windings are connected in series.

16. The method of claim 1 , wherein the insulation strip is wider than the conductor strip.