Transformers are the workhorses of the electronics industry. Except for some newer, modern technologies, almost every electronic device contains a transformer. With so many devices in such a wide range of applications the design and construction details are endless. 

One very important classification of transformers is the high voltage transformer. The field of high voltage transformers extends from very large power grid type transformers down to very small high voltage trigger transformers used for lighting a flash lamp. This category of transformers requires specialized winding techniques and specific high quality materials to produce. 

Custom Coils has been applying its expertise to high voltage transformer production for several decades. We specialize in transformers up to 35LBs, or approximately car battery size.  Over the years, we have developed techniques to isolate and insulate these transformers so that they will not break down under load. To keep this from happening, special attention must be taken to both isolate the primary from the secondary and also the secondary from the ground. We start this isolation process by choosing the correct winding technique for the design. We have the ability to wind on multi-section bobbins and multi-layer coil forms. When utilizing multi-layer windings, Kapton film, Nomex, Teflon, and several other materials can be used to insulate between the winding layers. If inter-winding capacitance is a concern, the use of a highly specialized winding technique, the universal pi wind can be implemented. 

This basket-weave style winding is becoming a lost art but is great for many high voltage transformer applications. Other transformer designs use a dielectric such as oil to isolate and cool the transformer. To help mitigate high voltage problems with outside components in an assembly, we have the ability to encapsulate our designs in one of several high quality epoxies.

We offer the ability to design and build many differ transformer types. Many specialized transformers are described throughout our website and more specific details can be found on the appropriate product page.

When it’s time to place a high voltage transformer order, Custom Coils will meet your needs. Just contact us to help design and quote your next transformer design. You’ll find our experience combines with our hands-on customer service to ensure that each order meets product specifications and exceeds quality expectations.