instructables

High Voltage Transformer

by How-ToDo

Hello everybody, how do you do? This is project
How-ToDo, my name is Konstantin and today I'll
make a high voltage transformer. I really like
experiments with high voltage, for some of them I
need AC power supply but industry unfortunately,
mainly offers transformers with built-in multipliers
after which we have DC, people who lives in Europe
can find transformers without multiplayers from old
Soviet TV. For me the only way left is to make
secondary coil by myself.

https://youtu.be/O1ik7Tuqh0s

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Step 1: Multi Section Bobbin

You can find good ferrite core in old TV, I'm using
core from CO2 laser power supply. There are lots of
videos on YouTube where people show how to make
a secondary coil, one dude makes 10 layers of tape
after each layer of coil, the other says you need to
boil the paper in paraffin, the third says that it isn't
good enough and you have to use a PVF film, there
are many ways to make a high voltage transformer,
and I'm pretty sure most of them are working well, but
if you are lazy like me, you'll become sick just from
one thought of winding at least one thousand turns
turn to turn and insolait it after each layer. Fortunately
we have an alternative - Multi Section Bobbin, the
idea is that in the place of the layers here sections in
the frame, which are filled with a wire, you can wind
in bulk, a little less efficient - but very simple. I made
a 12 section bobbin to the size of my core and print it
on 3d printer with PLA filament, filling is 100%.

Step 2: Winding Transformer

Clean supports with tiny file. I'm using 36 gauge enameled copper wire, and solder regular stranded wire to the
and, of course better to use special silicone wire, but I don't have it. Additionally I put a heat shrink tube, make one
turn on the first section and fill the enamel wire in next 10 sections, approximately 150 turns in each and 1500 in
total, and solder wire to the other side.

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Step 3: Filling With Epoxy Resin

After winding is done, we need to isolate the coil with
an epoxy resin, I tried to make a mold with paper and
tape, but it didn't work well. So I print this kind of a
cup, make holes for output wires and sealed it with
hot glue. Pour the epoxy with a little bit extra, it will
shrink when dry. This time it works much better. Also
it would be good to put the mold into a vacuum
chamber, but I don't have it, so there are few small air
bubbles inside. After coil was dry I grind it where it
necessary to fit the core.

High Voltage Transformer: Page 4

Step 4: Final

You can you use popular circuits to power this transformer such as ZVS driver or circuit on 555 timer, I made my
own driver on arduino, because I need to control the frequency, if you interested I can make a video about it. Only
one thing I don't like about this transformer is ionization near to the core, next time need to make walls a little bit
thicker. And that's all I got for today, hope you like it, see you soon!

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