An electric coil is made up of two distinct parts: a conductor and a core. Typically, the conductor is solid copper wire wrapped around a metal core. A turn is formed by looping the wire around the core, and multiple turns shape a coil. It functions as an electrical conductor, efficiently transmitting current to generators, electric motors, electromagnets, and inductors.
An electric coil’s most common application is as an inductor, which stores energy inside its electric field. An inductor, as a passive electrical component, has no gain and hence cannot regulate the directional flow of energy. It instead absorbs energy from the electric current that flows through its body.
Difference between an Encapsulated and Potted Coil
Like any other electrical coil, an encapsulated or potted coil is made by wrapping a ferromagnetic metal wire into a specific diameter. It’s an electromagnet that only works when exposed to electric currents. Encapsulated coils are frequently molded into liquid or thermoformed epoxies to protect them from harsh environmental conditions such as salt, water, moisture, and vibration. The coil is fused to its casing as a result of this procedure.
Encapsulated and potted coils are surrounded and sealed by liquid materials such as silicone rubber, epoxies, and polyesters. These materials are available in temperatures ranging from 105 °C to 190 °C.
The main difference between the encapsulated and potted coil procedures is the tooling: encapsulation uses a reusable mold into which the coil is put, filled with material, and removed after curing. However, potting employs a single-use cup, which becomes a component of the finished product.
Advantages of Using Encapsulated or Potted Coils
- Encapsulated or potted coils have excellent dielectric and isolation qualities and homogeneous dimensional and cosmetic attributes. As a result, they frequently offer superior protection against adverse climatic conditions than molded coils.
- Furthermore, because epoxies such as silicone rubber are dipped and thermoformed into sealing liquid, they provide vibration protection that molded casings do not. After production, encapsulated coils can be heat-treated, which sinters the plastic component with the molded coil inside, giving excellent protection.
- Encapsulating and potting techniques aid in heat transfer and protect components from thermal shock and harsh working environments such as grease, salt, water, humidity, and gasoline.
- Finally, when a protective outer shell is required, they give a cost-effective alternative to over-molding, as over-molding tooling can be costly and problematic in small quantities of order.
Shreejee Electronics’s Encapsulated Coil Manufacturing
Shreejee Electronics manufactures customized encased coils that are resistant to the most extreme weather conditions. Our experts choose the optimum encapsulating material based on the customer’s application, such as thermoplastics, thermosets, epoxies, silicone rubber, and polyesters.
We use vacuum chambers, vacuum ovens, and curing ovens to guarantee a proper cure regardless of the material utilized.
Our company manufactures encapsulated coils with temperatures ranging from 105 to 240 degrees Celsius. We rigorously test these coils to ensure that we meet all specifications, including hi-pot, inductance, resistance, leak, and surge testing.