1. Field of the Invention
[0001] The present invention relates to two-part transformer casings for high voltage communications
transformers and, more particularly, to two-part casings receiving hot liquid potting
material in the course of manufacture.
BACKGROUND OF THE INVENTION
[0002] The standard two-part transformer casings now in use for high voltage transformers
in the communications field consist of a main casing which has a groove or channel
of rectangular cross-section into which the cover is slidably inserted. During manufacture,
hot liquid potting material, e.g. epoxy, is poured into the case which is then subjected
to a vacuum to remove entrapped air. In the past, leakage around the casing-cover
seal occurred frequency during this process. To eliminate such leakage, sealers or
adhesives were necessary which added to the cost of production.
SUMMARY OF THE INVENTION
[0003] It is an object of the present invention to provide a transformer casing in which
a liquid-tight mechanical seal is achieved when one part is slid into the other, without
use of any additional sealing material.
[0004] It is a further object of the present invention to accomplish this end without departing
from the material presently in use and without departing from the molding techused
to manufacture both parts of the casing.
[0005] In accordance with the invention, the transformer casing has a first part having
a channel adapted to receive a second part slidably inserted therein. The channel
has a substantially U-shaped cross-section defined by a first rigid member and a second
flexible member extending in a direction substantially parallel to said first member
at a predetermined distance therefrom and connected to the first member at a first
extremity thereof. The second part has a projecting member substantially wedge-shaped
in cross-section and extending into the channel to form the mechanical connection
between the first and second part. The wedge has a maximum height in the direction
perpendicular to the rigid and flexible member which slightly exceeds the predetermined
distance between the latter. The height decreases in a direction extending towards
the first extremity of said flexible member so that the contacting surface between
the projecting member of said second part and the rigid member of said first part
substantially exceeds the contact area between said projecting member of the second
part and the flexible member of said first part . As a result of this construction,
the flexible member exerts a sealing force onto the projecting member of the second
part pressing it against the rigid member, thus creating a tight mechanical seal.
In addition, a second or back-up seal is formed at the contact between the flexible
member of the first part and the projecting member of the second part of the casing.
[0006] In a preferred embodiment, the first part is molded as a single unit, the flexible
member being a tapered beam having a substantially decreased cross section at the
extremity contacting the projecting member of the second part.
[0007] The present invention, as well as additional objects and advantages thereof, will
be more fully appreciated from the following detailed description when considered
in connection with the accompanying drawing in which:
BRIEF DESCRIPTION OF THE DRAWING
[0008]
Fig. 1 is a cross-sectional view of a prior art mechanical joint between cover and
case; and
Fig. 2 is a cross-sectional view indicating problem areas for the mechanical joint
shown in Fig. 1;
Fig. 3 is an exploded view of a transformer casing and cover to be slidably inserted
therein;
Fig. 4 is a cross-sectional view of the mechanically sealing joint of the present
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0009] The transformer casing shown in an exploded view in Fig. 3 consists of a main casing
(or first part) 10 and a cover (or second part) 12. The cover is to slide into the
main body in the direction of the arrow. Since the body of the casing contains heated
liquid epoxy potting material after the cover is inserted, a liquid-tight seal must
be established between the cover and the body of the casing to prevent leakage of
the potting material.
[0010] Although transformers casings of the ab- ovedescribed type have been commercially
available for approximately 6 years, sealers or adhesives were used during production
because of potting compound leakage. The prior art mechanical seal illustrated in
Figs. 1 and 2 illustrate the reason for such leakage. The channel in the main casing
is defined by a first and second member, 20, 22 extending in a direction parallel
to one another and separated by a distance H forming the height of the channel. Cover
12 has a projection or lip 24 which extends into the channel and whose height is somewhat
smaller than the distance H between members 20 and 22. It must be noted particularly
that member 20 and 22 have a similar cross- section, both crosssections being sufficiently
large to render the members rigid. With two such rigid members, a clearance must be
left between cover and case, i.e. the distance H between the facing surfaces of members
20 and 22 must slightly exceed the height H, of the cover projection. In the design,
the clearance must have a sufficient magnitude to compensate for tolerances in the
size of the parts introduced by the molding process. It must further allow for variations
in flatness of the mating surfaces of cover and case. These required clearances make
a mechanical seal impossible.
[0011] A deliberate design interference to allow mechanical sealing would be impossible
with this prior art transformer casing, since first, it would require very high force
to slide the cover into the case and, secondly, a highly stressed corner would be
created (see Fig. 2) which could easily result in breakage.
[0012] The above-mentioned problem is avoided by the construction of the present invention
as will be explained with reference to Fig. 4. In Fig. 4, the case has a first member
22' which is rigid as it was in the case illustrated in Figs. 1 and 2. As previously,
the second member 20' is connected to member 22' at one extremity 24. However, the
cross-sectional area of second member 20' decreases as the member extends from its
first extremity 24 in a direction parallel to the first member to form a U-shaped
channel. The decrease in cross-section causes the free end portion 25 of member 20'
to be flexible. Additionally, a lip 26 which projects from the cover and is to be
inserted into the Ushaped channel has a first portion 27 with wedge-shaped crosssection
and a second portion 28 witch a rectangular crosssection. Specifically, the cross-sectional
area of wedgeshaped portion 27 decreases as it extends into the channel in the direction
towards the bottom of the "U". The wedge shape is such that contact is maintained
with rigid member 22' after contact with flexible member 20' is made. The flexibility
of member 20' permits design interference between cover and case without creating
undue stress in the member. Further, it causes a downward sealing force to be applied
to projecting member 26', so that its bottom surface is tightly pressed against the
top surface of member 22'. A liquid-tight seal is thus formed.
[0013] If, contrary to expectation, liquid does escape through the seal formed by members
22' and 26, such liquid would still be sealed into the unit by the back-up seal formed
by contact between portion 28 of lip 26 and flexible end portion 25 of member 20.
[0014] The stress at the corners noted in the prior art joint can be further reduced by
rounding the junction of the flexible member with the base of the U with a radius
R. Similarly, the junction with the rigid member should be somewhat rounded to prevent
stress concentration. Finally, the maximum cross- section of the flexible member is
maintained at the first extremity to absorb stress safely.
[0015] In the preferred embodiment, the legs of the U forming the channel extend in the
horizontal direction. The U could also extend in a vertical direction, but gravity
or some other force might in that case cause separation between the mating parts unless
some external lock were added to the design.
[0016] In a preferred embodiment, just as in the prior art, the channel forming members
are a molded unit, as is the cover with its projecting member or lip.
[0017] A preferred embodiment may be described as follows:
Material: PBT (20% glass) Celanese 3210
Length of rigid member: .100 inch
Length of elastic member: .100 inch (decreasing cross-section only)
Distance between rigid and flexible member: .057/.060 inch
Maximum height of projecting portion of cover: .064 inch
Taper of projecting member: 6°
[0018] Length of contact of projecting member and rigid member: .068 inch
[0019] Length of contact of projecting member and flexible member: .040 inch
[0020] It is seen that by means of the present invention, a liquid-tight mechanical seal
can be achieved reliably, without requirement for additional parts or changes in the
manufacturing process of a transformer and without use of additional sealing compounds.
[0021] While the invention has been illustrated in a preferred embodiment, various modifications
and changes in the structure and operation thereof will be evident to one skilled
in the art and are intended to be encompassed in the following claims.
1. A transformer casing comprising:
a first part having a rigid member, and a flexible member extending in a direction
substantially parallel to said rigid member at a predetermined distance therefrom
and connected to said rigid member at a first extremity thereof, said rigid and flexible
member together forming a channel having a substantially U-shaped cross section;
a second part having a projecting member adapted to be inserted into said channel,
said projecting member having a first portion having a wedge- shaped cross section
and a first surface for contacting said rigid member to form a first mechanical seal,
said projecting member further having a second portion having a substantially rectangular
cross section and a second surface for contacting said flexible member to form a backup
seal; and
wherein said first surface is at a second distance from said second surface, said
second distance being at least equal to said predetermined distance.
2. A transformer casing as set forth in Claim 1, wherein said first surface has a
first surface area and said second surface has a second surface area; and
wherein said first surface area exceeds said second surface area.
3. A transformer casing as set forth in Claim 1, wherein said rigid member has a predetermined
crosssectional area; and wherein said flexible member has a first end portion including
said first extremity, and a free end portion, said free end portion having a second
cross section having a second cross-sectional area smaller than said predetermined
cross-sectional area.
4. A transformer casing as set forth in Claim 3, wherein said second cross-sectional
area decreases continuously in the direction extending toward said second surface
of said projecting member of said second part.
5. A transformer casing as set forth in Claim 1, wherein said first part including
said flexible and rigid members is formed as a single unit.
6. A transformer casing as set forth in Claim 1, wherein said first part of said casing
constitutes a housing receiving hot potting compound, and said second part is the
cover therefore.
7. A transformer casing as set forth in Claim 6, wherein said cover has ribs to help
prevent excessive warpage.