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terminating rubadue wire in flyback xfmr

Discussion in 'Electronic Design' started by Yzordderrex, Sep 26, 2005.

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  1. Yzordderrex

    Yzordderrex Guest

    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?

  2. Paul Mathews

    Paul Mathews Guest

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

    Yzordderrex Guest

    Thanks Paul!
  4. Pooh Bear

    Pooh Bear Guest

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

    What size conductor btw ?

  5. Pooh Bear

    Pooh Bear Guest

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

  6. Terry Given

    Terry Given Guest

    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 :)

  7. Pooh Bear

    Pooh Bear Guest

    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.

  8. Terry Given

    Terry Given Guest

    oh yes. connectors are indeed tricky things.
  9. Paul Mathews

    Paul Mathews Guest

    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
    Paul Mathews
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