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Abstract

An iron core transformer with at least one primary winding and at least one secondary winding of which at least one of the windings are wound with aluminum wire is disclosed for use in relatively low power applications, for example 5 kVa or below. The primary and secondary windings are connected to primary and secondary terminals. In order to overcome the effects of oxidation of the aluminum wire over time which can result in compromising the connection between the aluminum wire and its corresponding terminal, the terminals are formed as insulation displacement type terminals that are configured to strip any coatings or other contaminants on the aluminum wire during insertion of the aluminum wire into the terminal. The terminals are further configured to apply a constant spring biasing force against the aluminum conductor after it has been inserted. Thus, the transformer in accordance with the present invention is able to take advantage of the relatively low cost of aluminum wire, while at the same time providing stable connections between the aluminum wire and the transformer terminals. In order to facilitate the assembly of the transformer, in accordance with one aspect of the invention, a number of sockets are integrated into the bobbin for receiving the transformer terminals.

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First Claim