English

DTIC ADA098168: Manufacturing Methods and Technology for Electromagnetic Components. Volume 2. Phase 2

Various techniques for the manufacture of low cost, high reliability core type transformers/inductors for missile system applications were investigated and evaluated. A typical missile 'C' core high voltage inductor and toroidal core high voltage transformer were selected as representative test items. Molding technologies ranged from silicone or 'slush' molds for low quantities (100's/month), individually pressurizable hard molds (1000's/month), to liquid injection mold (LIM) with transfer presses (10,000/month). Over 40 encapsulation thermo setting compounds for high reliability components were tested and evaluated. Two compounds were selected, one optimum for low stress applications, the other for high voltage, corona free applications. Cure times are main limitation of production rates, pointing up a need for faster cure time materials of at least an order of magnitude. Winding techniques included establishing parameters for damage of fine wire windings on square bobbins, and a method of continuously monitoring insulation integrity of magnet wire during winding operations for both toroid, and bobbin/stick winders. Use of spot bonding instead of mylar tape to hold windings in pla

Sign in with your free account to read, download EPUBs or listen.