High frequency transformer widly used in industry application, here let's share how we make a customized EE65/32/27 transformer to our clients:

1 BOBBIN

16-pin bobbin with a 23mm x 30.6mm rectangular winding former. Length of the winding former is 39.66mm. Maximum depth of the winding is 8.2mm.

2 CORES

2 x E 65x32x27mm and F48 material.

3 WINDING

Use 3.25mm diameter solid copper wire.

The wire restraint hole between pins 2&3 on the bobbin needs to be increased in size to accommodate the large 3.25mm diameter wire. This restraint is the starting point of the winding pattern. The wire is wound over the entire length of the former (approx. 10 turns). The wire is wound back over the first layer, forming a second layer (approx. 11 turns). The final exit point of the winding is straight down.

A layer of high voltage transformer winding tape is applied on top of the completed winding pattern.

4 AUX WINDING

The auxiliary winding is wound on top of the completed main winding, using 0.53mm diameter wire:

LV & MV: no auxiliary winding

HV & XHV: 5 turns of auxiliary winding

Exit point of auxiliary winding is between pins 4 & 5 as marked with a white dot on the photo below.

Allow 60mm tails of auxiliary winding for soldering into PCB.

A layer of high voltage transformer winding tape is applied on top of the completed auxiliary winding pattern.

5 AIR GAP

The cores are to be gapped to 0.9mm. The air gap is currently realised with a wood product. However, any non-magnetic & non-conductive material can be used to set the gap. An acrylic adhesive is used to set the cores in place permanently, while a loop of transformer tape holds the cores in place while the acrylic sets.

Any similar request, please contact freely.