Method of manufacturing an amorphous metal transformer core and coil assembly

A method of manufacturing an amorphous metal core and coil assembly for a transformer comprising the steps of:

• A. forming a generally rectangular laminated core having four sides joined at corner regions and surrounding a core window, the core comprising essentially single-turn laminations arranged in superposed relationship and having a series of joints between the ends of said laminations situated in a localized joint region located within one of said sides, each said joint including opposed joint halves, each containing a plurality of said laminations, with radially adjacent joints being staggered, said one side including between said joint region and corner regions at opposite ends of said one side predetermined side portions that are displacable to separate said joints and open said core;
• B. annealing said core;
• C. restraining relative movement of said laminations in a region of said core removed from said joint region;
• D. separating said joints by displacing at least one of said predetermined side portions into a position of approximate alignment with the one side interconnected therewith at a corner region, thereby flexing the interconnecting corner region;
• E. applying to said one side portion and said interconnected side approximately aligned therewith a splint having a thin wall that at least partially surrounds said one side portion and at least a segment of said interconnected side, thereby holding said one side portion and said interconnected side in approximately aligned relation;
• F. inserting said one side portion, said interconnected side, and said splint as a unit into the bore of a preformed coil;
• G. sliding said splint off said one side portion and said interconnected side by moving said splint axially of said bore;
• and
• H. displacing said side portions into positions to remake said joints and thereby close said core about said coil with the coil positioned about said interconnected side.