Patent ID: 7788794

Claim:
A method of manufacturing a distribution transformer comprising: (a.) providing a core with a leg; (b.) providing a low voltage coil; (c.) forming a disc-wound high voltage coil comprising: providing an insulation spool comprised of an insulating material; providing an insulation strip; providing a conductor strip having a width to thickness ratio of greater than about 20:1; winding the insulation strip around the insulation spool; winding the conductor strip around the insulation spool; and wherein the winding of the insulation strip and the winding of the conductor strip are performed so as to form a plurality of disc windings arranged in an axial direction of the high voltage coil, and wherein each of the disc windings comprises alternating concentric layers of the conductor strip and the insulating strip; (d.) mounting the low voltage coil to the core; and (e.) mounting the high voltage coil to the core such that the leg extends through the insulation spool.