Segmented Core Cap Medical Transformers
Segmented core cap transformers place primary and secondary windings in alternate sectors to reduce leakage current.
Several modular insulating segments join together to form annular or semi-annular core caps for covering or partially covering a ring-type toroidal transformer core.
The core cap modules insulate windings from the core and allow for double-wall insulation between adjacent windings, significantly reducing leakage current compared to conventional toroidal transformers.
e.g. Compared a 1500VA Medical Grade Toroidal Transformer of standard construction: Maximum leakage current reduces from 81µA to only 14µA. (measured at 264V) giving a decrease of 83%. Also the leakage current at Hi-pot 5KV/50Hz/2sec reduced from 1030µA to 210µA, a decrease of 80%.
Segment Cap transformers also offer reduction in heat rise in comparison to standard toroidal transformers. Heat exchange is comparatively better on segment cap transformer because the design of the caps itself provides all the necessary insulation. Our findings show a reduction 13°C to 17°C temperature rise is a simple 1:1 isolation transformer.
UL Approval for Segment wound construction
UL investigated the Segment wound construction transformer as per standards UL60601-1 1st Edition, ANSI/AAMI ES60601-1 1st Edition, CAN/CSA C22.2 No 601.1 M90 and CSA C22.2 NO. 60601-1 2nd Edition Construction and determined that our segmented core cap transformer complies fully.
Get in touch and see how a Segmented Core Cap design can benefit your medical equipment, or use our custom toroidal transformer enquiry form.
See also our blog post explaining the construction and comparison with traditional toroidal transformers.
Talema have patented this design philosophy in USA, Europe, and Asia.