Cast Split Low Voltage Coil With Integrated Cooling Duct Placement After Winding Process

A method of providing cooling ducts in a coil of a transformer, the coil including a first coil segment and a second coil segment, method comprising the steps of:

• a) providing a first mold for the first coil segment,
• b) winding conductor sheeting around the mold to form a plurality of conductor layers,
• c) during the winding, placing spacers between certain of the conductor layers,
• d) placing segmented cooling ducts in channels created by the spacers,
• e) providing a second mold for the second coil segment,
• f) performing steps b) though e) to provide the second coil segment with spacers and cooling ducts,
• g) electrically connecting the first and second coil segments together so as to define a space between the coil segments,
• h) inserting cooling ducts into a cavities defined by the spacers in each of the first and second coil segments so as to define pairs of adjacent cooling ducts,
• i) for each pair of cooling ducts, connecting an end of a cooling duct disposed in the first coil segment with an adjacent end of a cooling duct disposed in the second coil segment, and
• j) removing the spacers.