Product Index

3M Transformer Application Guide

Wire-Wound Transformer

 

 

 

Application

 

 

 

Definition

 

 

 

Key Considerations in Selecting

Major Insulation

Applicable 3M  Flexible Insulation

 

Appropriate 3M  Insulating Tape*

 

 

CeQUIN

 

TufQUIN

 

ThermaVolt

 

ThermaVolt AR

 

 

Polyester

 

Filament Reinforced

Polyester Composite

 

 

Epoxy

 

Polyimide

 

 

Rubber

 

Acrylic

 

Rubber

 

Acrylic

 

Rubber

 

Rubber

 

Acrylic

 

Acrylic

Core Tube/ Ground Insulation

Insulation that is wrapped around bobbin or core. May also be supplied as preformed tube. [It is major when it is the sole insulation between windings and grounded or dead metal.]

•   Mechanical strength to resist cracking when wound around core

•   Sufficient dielectric strength to pass Hi-pot test

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

Layer Insulation

The material interleaved between successive layers of an insulated conductor in the same winding. Used in a mechanical application only, and does not serve as electrical insulation.

•   Sufficient mechanical strength to support wire layer to layer

•   No minimum thickness required

•   Minor insulation only

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

Turn Insulation

(or Conductor Wrap)

Insulation that is wrapped around bare conductor (in place of enamel coated wire).

•   Mechanical strength and elongation to support high speed winding

•   Resist damage during installation to prevent turn to turn failure

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

 

ü

 

 

 

 

 

ü

 

 

ü

 

 

 

 

 

 

Window Insulation/ Ground Insulation

(not shown)

A material used to supplement an air gap between a winding and grounded or dead metal. [It is identified as major when the air gap separating the insulation from the grounded or dead metal is less than 1/32 inch (0.8 mm).]

•   Must be able to be die punched and have good hinge strength at fold lines

•   If used as Major Insulation, must be able to pass Hi-pot testing

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

ü

 

 

ü

 

 

 

 

 

ü

 

 

Outer Wrap/ Ground Insulation

The material that is placed over the final layer of winding. [It is major when there is not a 1/32- inch (0.8-mm) minimum air gap separating it from grounded or dead metal.]

•   If used as a Major Insulation, must be able to pass Hi-pot testing

•   Mechanical strenth to protect wire windings

•   Cosmetic function

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

 

 

 

ü

 

 

ü

 

 

ü

Interwinding Insulation

The electrical insulation between Primary and Secondary windings (i.e., High-Low Barrier).

•   Sufficient dielectric strength to pass Hi-pot test

•   Mechanical strength to resist cut through (Wire wound over Hi-Low barrier is often pounded into shape)

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

 

 

 

 

 

 

Foil-Wound Transformer

 

 

 

Application

 

 

 

Definition

 

 

 

Key Considerations in Selecting

Major Insulation

 

Applicable 3M  Flexible Insulation

 

Appropriate 3M  Insulating Tape*

 

CeQUIN

TufQUIN

ThermaVolt

 

ThermaVolt AR

 

 

 

Polyester

 

Filament Reinforced

Polyester Composite

 

 

Epoxy

 

Polyimide

Rubber

Acrylic

Rubber

Acrylic

Rubber

Rubber

Acrylic

 

Acrylic

Core Tube/ Ground Insulation

Insulation that is wrapped around bobbin or core. May also be supplied as preformed tube. [It is major when it is the sole insulation between windings and grounded or dead metal.]

•   Mechanical strength to resist cracking when wound around core

•   Sufficient dielectric strength to pass Hi-pot test

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

Layer Insulation/ Turn Insulation

The material interleaved between successive layers of (uninsulated) foil

or strip conductor.

•   Sufficient mechanical strength to resist puncture from burrs on edge of foil

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

Outer Wrap/ Ground Insulation

The material that is placed over the final layer of winding. [It is major when there is not a 1/32- inch (0.8-mm) minimum air gap separating it from grounded or dead metal.]

•   If used as a Major Insulation, must be able to pass Hi-pot testing

•   Mechanical strenth to protect wire windings

•   Cosmetic function

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

 

 

 

ü

 

 

ü

 

 

ü

Interwinding Insulation

The electrical insulation between Primary and Secondary windings (i.e., High-Low Barrier).

•   Sufficient dielectric strength to pass Hi-pot test

•   Mechanical strength to resist cut through if wire is used in outer winding (Wire wound over Hi-Low barrier is often pounded into shape)

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

HID and Microwave Transformers

 

 

 

Application

 

 

 

Definition

 

 

 

Key Considerations in Selecting

Major Insulation

 

Applicable 3M  Flexible Insulation

 

 

Appropriate 3M  Insulating Tape*

 

 

CeQUIN

 

TufQUIN

 

ThermaVolt

 

ThermaVolt AR

 

 

 

Polyester

 

 

Filament Reinforced

Polyester Composite

 

 

Epoxy

 

Polyimide

 

 

Rubber

 

Acrylic

 

Rubber

 

Acrylic

 

Rubber

 

Rubber

 

Acrylic

 

Acrylic

Interwinding Insulation

The electrical insulation between Primary and Secondary windings (i.e., High-Low Barrier).

•   Sufficient dielectric strength to pass Hi-pot test

•   Mechanical strength to resist cut through (Wire wound over Hi-Low barrier is often pounded into shape)

•   For UL Systems, must meet EIS minimum thickness requirement

 

ü

 

 

ü

 

ü

 

ü

 

ü

 

 

 

 

 

 

 

 

 

Core Tube/ Ground Insulation

Insulation that is wrapped around bobbin or core. May also be supplied as preformed tube. [It is major when it is the sole insulation between windings and grounded or dead metal.]

•   Mechanical strength to resist cracking when wound around core

•   Sufficient dielectric strength to pass Hi-pot test

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

Outer Wrap/ Ground Insulation

The material that is placed over the final layer of winding. [It is major when there is not a 1/32-inch (0.8- mm) minimum air gap separating it from grounded or dead metal.]

•   If used as a Major Insulation, must be able to pass Hi-pot testing

•   Mechanical strenth to protect wire windings

•   Cosmetic function

•   Temperature class

•   For UL Systems, must meet EIS minimum thickness requirement

 

 

ü

 

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

ü

 

 

 

 

 

ü

 

 

ü

 

 

ü

 

Bobbin-Wound Transformer

 

 

 

Application

Applicable 3M  Flexible Insulation

 

Appropriate 3M  Insulating Tape*

 

CeQUIN

 

TufQUIN

 

ThermaVolt AR

 

 

 

 

Polyester

 

Paper Tape

 

Com- posite

 

 

 

Epoxy

 

 

 

Polyimide

 

 

 

 

 

Glass Cloth

 

 

Rubber

 

Acrylic

 

Rubber

 

Rubber

 

Rubber

 

Acrylic

 

Silicone Thermosetting

 

Acrylic

 

Rubber

 

Silicone

 

Acrylic

Start Lead

 

 

 

 

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

Lead Pad

ü

ü

ü

 

ü

ü

ü

ü

ü

ü

ü

ü

 

 

 

Lead Pad Hold-Down

 

 

 

 

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

End Lead Anchor

 

 

 

 

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

Interwinding Insulation

 

 

 

 

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

Outer Wrap/Ground Insulation

 

 

 

 

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

ü

黏貼纏繞 STICK-WOUND

Major Applications

Needs-Properties Required

Recommended Tapes

Layer Insulation Hold Down

固定絕緣包覆材質
  1. Holding (固定) - High bond adhesive to adhere to magnet wire and to layer insulation material (could be Nomex)
  2. Insulating (絕緣) - ECF of 1.0 on magnet wire 28 AWG or smaller.
 46, 1339, 44, MR94, MR94B, 1350, 1388, 1388, 1318

Lead Tap Anchor

固定漆包線線頭
  1. Holding (固定) - High bond adhesive to adhere to  magnet wire and adhesive-to-adhesive bond (cut and fold). Good edge tear resistance.
  2. Insulating (絕緣) - ECF of 1.0 on magnet wire 28 AWG or smaller.
 44,MR94, MR94B, 1350, 1388, 1388, 1318, 46

Up End and Cross Over
  1. Insulating High dielectric strength Usually must meet UL requirements. High bond adhesive to adhere to magnet wire and layer insulation (could be Nomex)
 44, MR94, 1350, 1388, 1318, MR94B, 46

Lead Pad & Lead Pad Hold Down

  1. Insulating (絕緣) - Minimal. Considered is series with the outer wrap. ECF of 1.0 on magnet wire 28 AWG and smaller.
  2. Holding (固定) - High bond adhesive to adhere to magnet wire, lead assembly material, pad tape. Edge-tear resistance to meet possible pullout requirements.
  3. Mechanical Protection, Cushioning - Puncture resistant. To prevent penetration of soldered connections. Hot solder resistance to avoid burn-through.
44, MR94, MR94B, 1350, 1388, 46, 1339

Coil Banding
  1. Holding (固定) - Good tensile, low stretch, high bond  adhesive to adhere to layer insulation (could be Nomex) and its own backing to avoid flagging. Conformability.
79, 1339, 46, 44, S10, S20

Terminal Strip Anchoring
  1. Holding (固定) - High bond adhesive to adhere to , layer insulation (could be Nomex) and S20 terminal strip material. Good tensile, Edge tear, puncture and hot solder resistance.
 44, 46, 1339, MR94, MR94B, 1350, 1388, 1318, S10

End Cap
  1. Insulating (絕緣) - Dielectric strength commensurate with  design requirements. High tack adhesive to adhere to layer insulation (could be Nomex). Conformability to avoid flagging. Adhesive must not contaminate varnish tank.
 44, MR94, MR94B, 55, 46, 56, 54

Outer Wrap
  1. Insulating (絕緣) - Dielectric strength should be , commensurate with design 1318 requirements. ECF of 1.0 with wire 28 AWG or smaller if in contact with wire.
  2.  Mechanical Protection - Puncture resistance to penetration by soldered connection. Edge-tear resistance to meet pull-out requirements.
  3. Holding (固定) - High bond adhesive to adhere to layer insulation (could be Nomex) and to its own backing. Flagging resistance in solvents.
  4. Identifying - Printable and stripeable (used for color coding)
 44, MR94, MR94B, 55, 11, 28, 1350

 

線圈捲線纏繞  BOBBIN-WOUND COILS

Start lead
  1. Holding (固定) - Quick stick to bobbin and to magnet , wire. Thin tape usually required.
  2. Insulating (絕緣) -Dielectric strength commensurate with application. ECF of 1.0 on magnet wire 28 AWG or smaller.
56, 1350, 1388, 1318, 1, MR94, MR94B, 92, 1205, 74, 1, S10, S20
Lead Pad

  1. Insulating (絕緣) -Dielectric strength commensurate with application. ECF of 1.0 on magnet wire 28 AWG or smaller.
  2. Mechanical Protection - Resistance to penetration by solder burrs or other pointed objects. Must be resistant to hot solder if connection is made on coil.
  75, 56, 1350, 1388, 1318, MR94, MR94B, 44
Lead Pad Hold Down

  1. Insulating (絕緣) -Dielectric strength commensurate with application. ECF of 1.0 on magnet wire 28 AWG or smaller.
  2. Holding (固定) -Third hand. High bond adhesive to adhere to lead assembly material, pad tape and magnet wire. Good edge tear if used as outer wrap.
  3. Mechanical Protection Cushioning - Resistance to penetration of soldered connections.
 44, MR94, MR94B, 46, 1318, 1350, 1388, 1339
End Lead Anchor
  1. Holding (固定) - High bond adhesive to adhere to  magnet wire. Edge tear resistance.
  2. Insulating (絕緣) - Minimal  ECF of 1.0 for magnet wire 28 AWG or smaller.
 56, 1318, 1350, 1388, MR94, MR94B
Interlayer Insulation
  1. Insulating (絕緣) - Quick stick to magnet wire.  Dielectric strength commensurate with the application. Cut-through resistance sufficient for the application, wire size, temperature. Conformability to fillet bobbin flanges to prevent wind downs.
 1350, 1388, 1318, 56, 1, S10, S20, 44, MR94, MR94B, 92, 60
Outer Wrap (Coil Cover)
  1. Mechanical Protection - Quick stick and high bond adhesive to adhere to magnet wire and avoid  flagging.   Solvent resistance required in some applications, with no thermosetting cycle in most cases. Puncture and hot solder resistance if lead connections are made.
  2. Insulating- Dielectric strength commensurate with application. ECF of 1.0 if used on magnet wire 28 AWG or smaller.  UL requirements balancing thickness and electric strength.  How many wraps currently used to achieve insulation required?
  3. Holding (固定) - Edge-tear resistance and high bond adhesive to meet lead pull requirements.
  4. Flame Retardancy - Company safety requirements to increase product reliability. (some Company component listing UL applications) Subject 510 material spec.
  5. Identifying - Printable and stripeable (used for color coding)
  6. Aesthetics - Smooth outer wrap conformable to fillet bobbin flanges. Opacity often required.
 1, 1350, 1388, 1318, S10, S20, 44, MR94, MR94B, 92, 60

 

電容器包覆塡充 WRAP AND FILL CAPACITORS

Outer Wrap

 
  1. Insulation - Quick stick to capacitor.  Dielectric strength commensurate with capacitor design.   Spec. No. E.C.F. of 1.0
  2. Identification - Ink receptivity of tape backing to produce clearly defined and well anchored printing.
  3. Environmental Protection - Solvent resistance. Specification No. 8 and test values expected.  Flagging resistance test method, if applicable.  Dielectric constant.  Operating temperature (Mostly 125° C)   Pertinent specification on overall capacitor performance.
 1, 1350, 1388, 1318, 1298, 56, S20

 

分馬力馬達 FHP Fractional Horsepower Motors

End Turn

  1. Holding (固定) -High bond adhesive to adhere to  magnet wire and own backing.    Resists flagging in solvents and heat during manufacturing and end use.
  2. Insulation - Dielectric strength commensurate with application. ECF of 1.0 on magnet wire 28 AWG or smaller.
 46, 44, MR94, MR94B, 1350, 1388, 1318(2mil)
Lead Connection

  1. Holding (固定) - High bond adhesive to adhere to wire and own backing. Resists flagging in solvents and heat during manufacturing and end use. Conformability.
  2. Insulation - Dielectric strength commensurate with application. ECF of 1.0 on magnet wire 28 AWG or smaller.
46, 44, MR94, MR94B, 1350, 1388, 1318 (2mil)
Lead Anchor

  1.  Holding (固定) - High bond adhesive to adhere to wire and our backing. Flagging resistance  in solvent and heat. Conformability. Good tensile strength. High temperature shear strength. Puncture resistant.
 46, 44, MR94, MR94B, 1350, 1388, 1318 (2mil)

基材特色概略 Summary of Selected Backings

Properties

Glass Cloth

Polyester Film

Cotton

Acetate Cloth

Paper

Reinforced

Polyester Film

Reinforced

Flame Retard.

Epoxy Film

Dielectric Strength

(volts)

2500-3000

5000

2000-3000

1500-2000

5000

6500

Thickness or Caliper

(mils)

7.0-7.5

2.2-3.2

8.0-10.5

5.0-9.0

5.0

5.5

U.L. Temp.

Recognition

Yes1

Yes(130°C)

No

No

Yes(130°C)

Yes(150°C)

U.L. Flame Retardant

Recognition

No2

No3

No

No

No

Yes

Tear Resistance

Excellent

Good

Poor

Poor

Good

Good

Conformability

Excellent

Poor

Excellent

Good-Exc.

Good

Good

Electrolytic Corrosion

Factor

1.0

1.0

Acetate-1.0

Cotton-.85

.8

1.0

1.0

Hot Solder Resistance

Good

Poor

Poor

Excellent

Good

Excellent

Puncture Resistance

(lbs.)

18-30

9.5

Acetate-9.2

Cotton-16

2.7-7.6

14

11.5

Tensile Strength

(lbs./inch)

150-180

20-25

40-50

35-45

40

40-50

Temperature Class

See1

130°C

105°C

105°C

130°C

130°C

1Temperature rating is dependent upon adhesive system.

2Except when an electrical grade silicone adhesive system is used.

3Except when specially formulated flame retardant polyester film tape is used.

*All values shown are typical and are not intended for specification purposes.

 

 

中央商業有限公司 Power Hub Inc.