Methods of manufacturing toroids

Abstract

A method of manufacturing a first toroid 214, comprising: unspooling a strip 210 from a first spool 202 which has a longitudinal axis; during unspooling, cutting the strip (cutters 206, e.g laser / mechanical) into a first oval (ellipse) 212 having one axis of symmetry parallel to longitudinal axis of strip; and winding the first oval onto a second spool 204 (mandrel, reel) to form the first toroid 214, all actions occurring preferably contemporaneously. During unspooling, the strip may be cut into a second oval 212 having one axis of symmetry, which is also parallel to the longitudinal axis of the strip; and winding the second oval onto a third spool. This may directly form a second toroid or a second toroid may be formed by spooling from the third to a fourth spool. The first and second ovals may be parallel to one another and form a tessellated shape when viewing the strip in plan view. The strip may be a strip of material having a high magnetic permeability such as bond coated electrical steel. One embodiment also describes a toroid manufactured using the method. The one or more toroids may be used as magnetic core formers for electrical devices (e.g transformers, inductors, motors). May be used to form three phase transformers by joining toroids cut into equal parts (see figures 6A-C). Figures 3A and 4