Process for manufacturing an electrical-power transformer having phase windings formed from insulated conductive cabling

A process for manufacturing an electrical-power transformer, comprising:

• stacking a plurality of laminae to form a first, a second, and a third winding leg and an upper and a lower yoke;
• fixedly coupling the first, second, and third winding legs to the lower yoke;
• fixedly coupling the first, second, and third winding legs to the upper yoke;
• and
• winding a first length of insulated conductive cabling on the first winding leg to form a first phase winding, winding a second length of the insulated conductive cabling on the second winding leg to form a second phase winding, and winding a third length of the insulated conductive cabling on the third winding leg to form a third phase winding after coupling the first, second, and third winding legs to the upper and lower yokes, wherein the insulated conductive cabling comprises a conductor, a first layer of semi-conductor material surrounding the conductor, a layer of electrically-insulating material surrounding the first layer of semi-conductor material, and a second layer of semi-conductor material surrounding the layer of electrically-insulating material.

A process for manufacturing a magnetic-induction device, comprising:

• forming a plurality of laminae from a sheet of magnetic material;
• stacking the plurality of laminae to form a winding leg, a first yoke, and a second yoke;
• fixedly coupling a first end of the winding leg to the first yoke;
• winding a length of insulated conductive cabling on the winding leg to form a phase winding after fixedly coupling the winding leg to the first yoke;
• and
• fixedly coupling a second end of the winding leg to the second yoke after forming the phase winding.

A process for manufacturing a magnetic-induction device, comprising:

• forming a plurality of laminae from a sheet of magnetic material;
• stacking the plurality of laminae to form a winding leg, a first yoke, and a second yoke;
• fixedly coupling a first end of the winding leg to the first yoke;
• fixedly coupling a second end of the winding leg to the second yoke;
• and
• winding a length of insulated conductive cabling on the winding leg to form a phase winding after fixedly coupling the winding leg to the first and second yokes, wherein the insulated conductive cabling comprises a conductor, a first layer of semi-conductor material surrounding the conductor, a layer of electrically-insulating material surrounding the first layer of semi-conductor material, and a second layer of semi-conductor material surrounding the layer of electrically-insulating material.

A process for manufacturing an electrical-power transformer, comprising:

• assembling an E-core;
• winding a first length of insulated conductive cabling on a first winding leg of the E-core to form a first phase winding, winding a second length of the insulated conductive cabling on a second winding leg of the E-core to form a second phase winding, and winding a third length of the insulated conductive cabling on a third winding leg of the E-core to form a third phase winding after assembling the E-core;
• and
• fixedly coupling an upper yoke to the E-core after forming the first, second, and third phase windings.