Transformer Bobbin Frame Non-compliance with Safety Regulations: If the wall thickness for UL test PM-9630 is 0.39mm, any wall thickness below this is likely to result in poor voltage resistance. If the mold is fine during mass production but not during the manufacturing process, it may be due to eccentricity or misalignment of the mold, causing uneven wall thickness. The main raw material and its characteristics of transformers are the magnetic medium, specifically the magnetic core. The primary materials构成线圈 consist of the frame (bobbin), wire material, insulating film (tape, paper), insulating varnish, and auxiliary materials.
The Transformer Bobbin is a device that converts electromagnetic energy through the use of an iron core and winding. The performance of the iron core material and the correctness of its selection will determine the performance of the transformer.
Transformer bobbin manufacturing often encounters various issues, which require specific analysis for each case. Some HIPOT failures are often caused by a combination of several factors, necessitating analysis to resolve the problem. This demands that we not only be proficient in our professional manufacturing techniques, material characteristics, mold structures, and machine performance, but also understand the manufacturing processes of transformer manufacturers, the properties of vanishing oil, the method of rubber coating, etc., in order to more effectively address the issues.
Transformer bobbin frame non-compliance with safety regulations for wall thickness; for example, in UL test PM-9630, the minimum wall thickness is 0.39mm. If your wall thickness is below this, poor dielectric strength is expected. If the mold production is fine but there are issues during the manufacturing process, it may be due to eccentricity or misalignment of the mold, causing uneven wall thickness.
During the molding process, inadequate debugging can lead to poor pressure resistance (and temperature resistance) issues. These two problems often occur simultaneously, primarily due to inappropriate adjustment of molding parameters. If the temperature of the bakelite mold is too low (or too high) or uneven, it may result in insufficient chemical reaction of the bakelite material, leading to incomplete molecular chains and poor pressure and temperature resistance. Additionally, if the injection pressure and speed are too low, it may cause insufficient product density, resulting in poor pressure and temperature resistance.
