Publications Details
High voltage transformer design iterations to meet high-rel requirements
This paper describes a high-rel transformer design and the design iterations required to meet the severe environments of military grade transformers. It describes a method of reducing the mechanical stress caused when a ferrite pot core is encapsulated in a rigid epoxy. Stresses are due to differences in coefficient of thermal expansion between the two materials. The mechanical design optimization of a small flyback transformer designed to charge an energy storage capacitor up to 6 kV from a low voltage source is described. The basic design uses a 2616 manganese zinc ferrite pot core. The goal was to eliminate the core cracking problem. The purpose for writing and presenting this paper is to document a proven process that evolved out of necessity, and to present to the industry a method which reduces stresses on the core, eliminates cracking of the core and provides the insulation necessary for small high voltage transformers.