Extreme duty encapsulated transformer coil with corrugated cooling ducts and method of making the same

Abstract

Methods and devices for an extreme duty transformer with wet wound primary and secondary winding encapsulated with a resin and having corrugated insulating material as cooling ducts as a transformer capable of withstanding extreme mechanical stresses in an underground mining environment. The method includes providing a resin impregnated rectangular winding form, forming a secondary winding with alternating layers of magnet wire with a resin impregnated insulating collar above and below the magnet wire and corrugated insulating material extending the full or partial circumference and width of the coil. An insulating layer of corrugated material and resin impregnated insulation is wound to separate the primary from the secondary windings. The primary winding is wound with alternating magnet wire layers and resin impregnated insulation layers and a resin impregnated outer layer covers the circumference of the coil to produce an oval mechanically robust construction preventing winding displacement and sealing out environmental contaminants.