Transformer core

A method of forming a transformer core, comprising:

• obtaining a first side limb component;
• obtaining a second side limb component;
• cutting a first lamination strip to obtain a plurality of upper yoke segments that are trapezoidal in structure to form an upper yoke component, wherein the plurality of the upper yoke segments are cut consecutively from the first lamination strip as alternate upright and inverted trapezoids, and disposing the upper yoke component between an upper end of the first side limb component and an upper end of the second side limb component;
• cutting a second lamination strip to obtain a plurality of lower yoke segments that are trapezoidal in structure to form a lower yoke component, wherein the plurality of the lower yoke segments are cut consecutively from the second lamination strip as alternate upright and inverted trapezoids, and disposing the lower yoke component between a lower end of the first side limb component and a lower end of the second side limb component;
• forming an intermediate limb component from a first intermediate limb segment and a second intermediate limb segment and disposing a first end of the intermediate limb component between two consecutive upper yoke segments and a second end of the intermediate limb component between two consecutive lower yoke segments;
• and
• joining the first side limb component, the second side limb component, the intermediate limb component, the upper yoke component, and the lower yoke component to form a lamination layer of a transformer core.

A transformer comprising:

• a transformer core comprising:
• a plurality of lamination layers, at least one lamination layer of the plurality of lamination layers comprising:
• a first side limb component;
• a second side limb component;
• an upper yoke component disposed in between an upper end of the first side limb component and an upper end of the second side limb component, the upper yoke component comprising one or more upper yoke segment;
• a lower yoke component disposed in between a lower end of the first side limb component and a lower end of the second side limb component, the lower yoke component comprising one or more lower yoke segments;
• and
• an intermediate limb component comprising a first intermediate limb segment and a second intermediate limb segment, wherein a first end of the intermediate limb component is disposed in between two consecutive upper yoke segments and a second end of the intermediate limb component is disposed in between two consecutive lower yoke segments,
• at least one of the upper yoke segment and the lower yoke segment being trapezoidal in structure;
• and
• a plurality of windings wound on the transformer core.