Patent ID: 8198973

Claim:
A transformer comprising an iron core made by forming an amorphous ribbon toroidally in a plurality of layers; and an exciting coil, wherein at least one insulating thin film having a thickness of approximately 1 μm is formed from at least one silicone material on at least one side of the amorphous ribbon for each of the plurality of layers of the amorphous ribbon forming the iron core by vapor deposition treatment during a manufacturing process to machine an amorphous ribbon material into a transformer iron core, the iron core is made by a process comprising the steps of: unwinding an amorphous ribbon material from a hoop; vapor depositing a thin insulating film of silane on at least one major surface of the amorphous ribbon material while the amorphous ribbon material is unwound from the hoop, wherein the step of vapor depositing a thin insulating film of silane comprises passing the amorphous ribbon material into a deposition apparatus, through a gaseous shielding layer, and into a reaction chamber filled with evaporated silane, and then passing the amorphous ribbon material through the gaseous shielding layer and out of the deposition apparatus; cutting the amorphous ribbon material into a plurality of segments having a specified length; stacking the plurality of segments of the amorphous ribbon material so that major surfaces of adjacent segments are opposed to one another with the thin insulating film therebetween to form a laminate; and toroidally winding the laminate.