terminating rubadue wire in flyback xfmr

[Yzordderrex]

I am trying to design a flyback transformer. The feedback winding will
be 15v and there will also be a 5v winding as well. There will also be
a tertiary winding to supply 15v to the customer and to power a 12v fan
on the larger units.

European standards like VDE and IEC and CE and on and on and on tend to
complicate the designs so that I would like to use flying leads of
triple insulated wire for the customer winding. Is it possible to use
an insulation displacement type of a connector on the triple insulated
Rubadue or Furukawa TEX-E types of wire?

thanks,
Bob

 

[Paul Mathews]

Yes. The thin PTFE layers displace relatively easily.
Paul Mathews

 

[Yzordderrex]

Thanks Paul!

 

[Pooh Bear]

I am trying to design a flyback transformer. The feedback winding will
be 15v and there will also be a 5v winding as well. There will also be
a tertiary winding to supply 15v to the customer and to power a 12v fan
on the larger units.

European standards like VDE and IEC and CE and on and on and on tend to
complicate the designs so that I would like to use flying leads of
triple insulated wire for the customer winding. Is it possible to use
an insulation displacement type of a connector on the triple insulated
Rubadue or Furukawa TEX-E types of wire?

No. IDC termination requires a PVC covering. Anything else will be
unreliable.

What size conductor btw ?

Graham

 

[Pooh Bear]

Yes. The thin PTFE layers displace relatively easily.
Paul Mathews

It's not PTFE. Using an unapproved cable with IDC is likely to lead to
long term problems.

Graham

 

[Terry Given]

Yzordderrex wrote:




No. IDC termination requires a PVC covering. Anything else will be
unreliable.

What size conductor btw ?

Graham

no. IDC requires suitable Cu OD and insulation thickness, thats all.

I've done it with Furukawa TEX-E, but only a few hundred thousand times
in a high-reliability industrial product

Cheers
Terry

 

[Pooh Bear]

no. IDC requires suitable Cu OD and insulation thickness, thats all.

I've done it with Furukawa TEX-E, but only a few hundred thousand times
in a high-reliability industrial product

Did you check with your connector vendor first though ? ;-)

IDC termination can be very touchy. One company I was with had a problem once
with unreliability that simply stemmed from using the flat cable when it
wasn't warm enough.

Graham

 

[Terry Given]

Terry Given wrote:




Did you check with your connector vendor first though ? ;-)

oh yes. connectors are indeed tricky things.

IDC termination can be very touchy. One company I was with had a problem once
with unreliability that simply stemmed from using the flat cable when it
wasn't warm enough.

Graham

Cheers
Terry

 

[Paul Mathews]

I assumed that you were referring to Rubadue or similar
'triple-insulated wire'. This wire has 3 layers of thin insulation
compounded from Teflon, Tefzel, or other material similar to PTFE. (I
have no idea why Graham insists on contradicting me.)
Here are 2 requirements for successfull IDC termination:
1) Insulation must displace or 'cold flow'
2) Contact spring-form must maintain pressure on wire so that
connection is 'gas tight'.
Obviously, requirement #2 implies that the wire and the contact be
'compatible', i.e., the contact must be engineered to fit the wire.
Owing to the bulk of the resulting termination, I've gone away from IDC
termination on my miniature transformer designs in favor of solder.
TIW strips easily using the appropriate heat settings on a thermal
stripper.
Paul Mathews