Bobbin Winding Process Photo Gallery

The first winding on the bobbin using magnet wire – coated for electrical insulation

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Applying the overwinding insulation with Mylar adhesive tape – providing additional electrical insulation between windings

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The second winding on the bobbin – also coated for electrical insulation. The wire may be the same as the first winding, or it may not.

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After the transformer has been wound, terminated to the pins it is soldered, and cores inserted. A clamp is used to hold core halves together until cement is cured.

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Once the core is inserted, the transformer is tested to ensure customer specifications are met. Every transformer is tested at Butler Winding before delivery.

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Insertion of lamination pieces, made of silicon steel, to form core of transformer. Bobbin wound transformers and bobbin wound inductors both go through this process.

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Butler Winding records manufacturing steps and feedback during the construction process.

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Toroidal transformers ready to be encapsulated in a potting shell.

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Potting (hermetic sealing) will occur towards the end of the manufacturing process to protect the transformer from debris and moisture.

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Potting (hermetic sealing) will occur towards the end of the manufacturing process to protect the transformer from debris and moisture.

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