Abstract: A transformer assembly, particularly for data and audio signals, has first and second bobbins which are telescoped within one another. A method of assembling a transformer assembly is provided which comprises providing first and second bobbins, coils around the bobbins and, as a first step, slidably mounting the bobbins within one another. The core is preformed or comprises laminations formed as E's and I's, which are then fitted through the assembly cap and the bobbins. The cap provides a receptacle for the core, and retains the laminations in position. To secure the laminations in position, an assembly cup is mounted around the outside of the laminations. The assembly cup can include springs or the like, to maintain the laminations in position and allow for expansion and contraction. The springs can additionally mechanically secure the transformer in position. The bobbins, cap, core and cup can be encapsulated together.

Abstract: A transformer assembly, particularly for data and audio signals, has first and second bobbins which are telescoped within one another. An assembly cap is fitted around the bobbins and includes flanges for locating a core. The bobbins and the cap are designed such that creepage and clearance requirements are met. The core is preformed or comprises laminations formed as E's and I's, which are then fitted through the assembly cap and the bobbins. The cap provides a receptacle for the core, and retains the laminations in position. To secure the laminations in position, an assembly cup is mounted around the outside of the laminations. The assembly cup can include springs or the like, to maintain the laminations in position and allow for expansion and contraction. The springs can additionally mechanically secure the transformer in position. The bobbins, cap, core and cup can be encapsulated together.