Method of forming a transformer winding
A high current transformer winding made from a flat conductor having opposing ends that are shaped (e.g. a lateral protrusion), such that when a middle portion of the conductor is wound around a transformer core, one or both opposing ends protrude to allow operative connection to a power source.
1. A method of forming a transformer winding comprising the steps of:
obtaining a conductor, the conductor being substantially flat and elongate, and further having first and second opposing ends, and a middle portion, wherein the conductor has at least one coplanar lateral protrusion disposed proximate either of the first or second opposing ends of the conductor;
and winding the middle portion of the conductor to form a high current winding;
wherein each of the first and second opposing ends is adapted to be operatively connected to a power source.
2. The method of claim 1 further comprising:
a first lateral protrusion disposed proximate the first opposing end of the conductor;
and a second lateral protrusion disposed proximate the second opposing end of the conductor.
3. The method of claim 1 further comprising:
folding either or both of the first and second opposing ends of the conductor so as to form a turn.
4. The method of claim 3
wherein the turn is a laterally oriented turn.
5. The method of claim 3
wherein the turn is an oppositely oriented, substantially right angle.
6. The method of claim 1 further comprising:
the middle portion of the conductor is wound around the longitudinal axis at least two times.
7. The method of claim 1 further comprising:
the middle portion of the conductor is wound around a transformer core.
8. The method of claim 1 further comprising:
the middle portion of the conductor is wound around a bobbin.
9. The method of claim 1 further comprising:
operatively connecting the conductor to a heat sink.
10. The method of claim 1 further comprising:
forming a low current winding radially outside of, and concentric with the high current winding;
operatively connecting the low and high current windings to a portion of a transformer core.
11. The method of claim 10 further comprising:
placing the low current winding in physical proximity to a heat sink.
12. The method of claim 10 further comprising:
placing the low current winding in physical contact with a heat sink.
13. The method of claim 10 further comprising:
placing the low current winding in thermal contact with a heat sink.
14. The method of claim 10 further comprising:
placing the low current winding in thermal contact with a printed circuit board.