Encapsulated transformer
First Claim
1. An encapsulated transformer, comprising:
- a transformer coil assembly that includes a core having a hollow interior, primary wire windings and secondary wire windings;
at least one primary lead connected to the primary windings;
at least one secondary lead connected to the secondary windings;
a rigid core insert having an upstanding portion positioned within the hollow interior of the core and a base portion on which the transformer coil assembly rests, said core insert having a hole which extends through the base portion and into the upstanding portion wherein the base portion of said core insert has an end face which faces away from said upstanding portion, said end face having at least one groove formed therein that extends from the hole in the core insert to an outer edge of the end face to communicate the hole in the core insert with the outer edge of the end face;
a unitary thermoplastic rubber jacket surrounding the transformer coil assembly and bonded to the base portion of the core insert to provide a completely waterproof encapsulated transformer.
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Accused Products
Abstract
An encapsulated transformer includes a transformer coil assembly, a rigid core insert having an upstanding portion positioned within the hollow interior of the core and a base portion on which the core rests, and a thermoplastic rubber jacket that completely surrounds the transformer coil assembly and is bonded to the base portion of the core insert to provide a completely waterproof encapsulated transformer which is impervious to liquid and gasses that could be detrimental to the performance of the transformer. A method for producing such an encapsulated transformer includes placing a rigid core insert in a mold cavity of a mold, and positioning a transformer coil assembly in the mold cavity so that the transformer coil assembly rests on the core insert. Thermoplastic rubber is then injected into the mold cavity to completely encapsulate the transformer coil assembly in a jacket of thermoplastic rubber. During the injection step, gas in the mold cavity is vented through a vent space provided in the bottom surface of the mold cavity. A mold for encapsulating a transformer coil assembly in thermoplastic rubber includes a bottom mold portion having a mold cavity, an upstanding pin disposed within the mold cavity, a mold cover for closing the mold cavity, and a vent space positioned in the bottom surface of the mold cavity for venting gas within the mold cavity to the exterior of the mold during the injection of thermoplastic rubber into the mold cavity.
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Citations
10 Claims
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1. An encapsulated transformer, comprising:
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a transformer coil assembly that includes a core having a hollow interior, primary wire windings and secondary wire windings; at least one primary lead connected to the primary windings; at least one secondary lead connected to the secondary windings; a rigid core insert having an upstanding portion positioned within the hollow interior of the core and a base portion on which the transformer coil assembly rests, said core insert having a hole which extends through the base portion and into the upstanding portion wherein the base portion of said core insert has an end face which faces away from said upstanding portion, said end face having at least one groove formed therein that extends from the hole in the core insert to an outer edge of the end face to communicate the hole in the core insert with the outer edge of the end face; a unitary thermoplastic rubber jacket surrounding the transformer coil assembly and bonded to the base portion of the core insert to provide a completely waterproof encapsulated transformer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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Specification