Method of making a molded transformer enclosure

A method of constructing an induction transformer having at least one primary coil and at least one secondary coil, said primary coil having leads to electrically connect to a source of current, and said secondary coil having leads to conduct current therefrom, comprising:

• assembling primary and secondary coils and means to maintain a flux density therearound in a manner to create an inductive subassembly having primary coil leads extending from the primary coil and secondary coil leads extending from the secondary coil;
• providing a mold having separable wall portions, each wall portion having at least one stub projecting inwardly of the mold, with the stubs being adapted to align with and contact each other when the mold is closed;
• seating the subassembly on a mounting means between the separable wall portions;
• interengaging the separable wall portions to close the mold around the subassembly;
• filling the mold with an epoxy resin to sealingly encapsulate the subassembly except for the primary and secondary coil leads;
• and
• allowing the epoxy resin to harden, thereby providing a molded enclosure about said subassembly, said molded enclosure having at least one premolded mounting hole integrally formed by the at least one stub for mounting the transformer to a support.

A method of constructing an induction transformer having at least one primary coil and at least one secondary coil, said primary coil having leads to electrically connect to a source of current, and said secondary coil having leads to conduct current therefrom, comprising:

• assembling primary and secondary coils and means to maintain a magnetic flux density therearound in a manner to create an inductive subassembly having primary coil leads extending from the primary coil and secondary coil leads extending from the secondary coil;
• providing a mold having a wall portion, said wall portion having at least one stub projecting inwardly of the mold;
• seating the subassembly adjacent the wall portion;
• filling the mold with an epoxy resin formed of equal parts of aluminum oxide and a nonfoaming, thermal-set epoxy to sealingly encapsulate the subassembly except for the primary and secondary coil leads;
• and
• allowing the epoxy resin to harden, thereby providing a molded enclosure about said subassembly, said molded enclosure having at least one premolded mounting hole integrally formed by the at least one stub for mounting the transformer to a support.

A method of constructing an induction transformer having at least one primary coil and at least one secondary coil, said primary coil having leads to electrically connect to a source of current, and said secondary coil having leads to conduct current therefrom, comprising:

• assembling primary and secondary coils and means to maintain a flux density therearound in a manner to create an inductive subassembly having primary coil leads extending from the primary coil and secondary coil leads extending from the secondary coil;
• providing a mold having separable, generally C-shaped wall portions, each wall portion having at least one stub projecting inwardly of the mold, with the stubs being adapted to align with and contact each other when the mold is closed;
• seating the subassembly on a plate disposed between the separable wall portions, said plate having apertures complementary in shape to the secondary coil leads so that the secondary coil leads project through the apertures when the mold is closed;
• interengaging the separable wall portions to close the mold around the subassembly;
• and
• filling the mold with an epoxy resin to sealingly encapsulate the subassembly except for the primary and secondary coil leads.