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The research reported herein adds to the understanding of oil-immersed distribution transformers by exploring and demonstrating potential improvements in efficiency and cost utilizing the unique Buswell approach wherein the unit is redesigned, replacing magnetic sheet with wire allowing for improvements in configuration and increased simplicity in the build process. Exploration of new designs is a critical component in our drive to assure reduction of energy waste, adequate delivery to the citizenry, and the robustness of U.S. manufacturing. By moving that conversation forward, this exploration adds greatly to our base of knowledge and clearly outlines an important avenue for further exploration. This final report shows several advantages of this new transformer type (outlined in a report signed by all of our collaborating partners and included in this document). Although materials development is required to achieve commercial potential, the clear benefits of the technology if that development were a given is established. Exploration of new transformer types and further work on the Buswell design approach is in the best interest of the public, industry, and the United States. Public benefits accrue from design alternatives that reduce the overall use of energy, but it must be acknowledged that new DOE energy efficiency standards have provided some assurance in that regard. Nonetheless the burden of achieving these new standards has been largely shifted to the manufacturers of oil-immersed distribution transformers with cost increasing up to 20% of some units versus 2006 when this investigation was started. Further, rising costs have forced the industry to look closely are far more expensive technologies which may threaten U.S. competitiveness in the distribution transformer market. This concern is coupled with the realization that many units in the nation's grid are beyond their optimal life which suggests that the nation may be headed for an infrastructure crisis that U.S. industry is ill prepared to handle which could further challenge U.S. competitiveness

Electrical Core Transformer for Grid Improvement Incorporating Wire Magnetic Components