Low voltage composite mold
View Patent ↗A transformer coil is produced by forming a sheet of composite material over a plurality of annular shaped support plates to form an inner layer. A coil is wound around the inner layer. An outer layer is formed by wrapping a sheet of composite material over the coil. The outer layer is mechanically attached to the coil. A base is attached to the coil assembly and epoxy is used to encapsulate the coil. The epoxy forms a bond with the inner and outer layers, which become an integral part of the transformer coil.
1. A method of manufacturing a transformer coil comprising the steps of:
forming an inner layer by wrapping a sheet of composite material over a plurality of annular shaped support plates;
winding a coil around the inner layer;
forming an outer layer by wrapping a sheet of composite material over the coil;
mechanically attaching the outer layer to the coil, thereby forming a coil assembly;
attaching a base to the coil assembly;
providing a seal between the base and the coil assembly to prevent epoxy leaks during the encapsulation process; and
filling the coil assembly with epoxy to encapsulate the coil.
2. The method of claim 1 wherein at least the inner layer becomes a part of the transformer coil.
3. The method of claim 1 wherein the inner layer and outer layer become part of the transformer coil.
4. The method of claim 1 wherein the composite material is an insulating material.
5. The method of claim 4 , wherein the composite material includes fiberglass.
6. The method of claim 1 , comprising forming a sealing layer between the inner layer and the coil.
7. The method of claim 1 , wherein the outer layer is formed by overlapping layers of the sheet of composite material.
8. The method of claim 1 , wherein the inner layer is formed by overlapping layers of the sheet of composite material.
9. A transformer coil comprising:
an inner layer;
a plurality of coil windings;
an outer layer; and
an epoxy material that encapsulates the coil windings and forms a first bond between the coil windings and the inner layer and forms a second bond between the coil windings and the outer layer, wherein
the inner layer and the outer layer each comprise a composite material.
10. The transformer of claim 9 , wherein the composite material is non-conductive.
11. The transformer of claim 9 , wherein the composite material is an insulating material.
12. The transformer of claim 11 , wherein the composite material comprises fiberglass.
13. The transformer of claim 9 , the inner layer comprising a sealing layer between the composite material and the coil windings.
14. The transformer of claim 9 , wherein the outer layer is formed by overlapping layers of the sheet of composite material.
15. The transformer of claim 9 , wherein the inner layer is formed by overlapping layers of the sheet of composite material.
16. The transformer of claim 9 , wherein the coil windings are formed from alternating layers of a conducting material and an insulating material.
17. The transformer of claim 9 , wherein the inner layer and the outer layer each comprise a sheet of composite material wrapped over a plurality of support plates.
18. The transformer of claim 17 , wherein each of the support plates has an annular shape.