Encapsulated Coil Manufacturing

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Endicott Coil Company, Inc. can design and manufacture custom encapsulated coils that withstand the harshest environmental conditions. Encapsulated coils shield the coil from the environment, provide high dielectric and isolation properties, and improve heat transfer. We will choose the right encapsulation material for the customer’s specific application. Commonly used materials include thermoplastics, thermoset, epoxies, silicone rubber, and polyesters. Presses with up to 30 tons of force ensure the coil is properly molded into the encapsulation material. Our vacuum chambers, vacuum ovens and curing ovens allow us to ensure a proper cure regardless of the material chosen.

Encapsulated coils can be manufactured for temperature ranges from 105°C to 240°C. We thoroughly test our coils using hipot, inductance, resistance, leak, and surge testing to ensure all of our customer’s specifications are met. ISO methodologies and procedures are used throughout the facility and we are experienced in ASTM, CSA, VDE, NRC, Mil-Spec, and UL testing procedures. We are also a RoHs compliant facility. Our engineering staff is capable of finding a manufacturing solution to meet our customers’ needs from prototypes to large volume production runs. For more information about our custom encapsulated coils, please see the table below, or contact us directly.

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Details of Endicott Coil's Custom Encapsulated Coil Manufacturing Capabilities

Product Name

Encapsulated Coils
Potted

Benefits

Protection from Harmful Environments
High Dielectric and Isolation Properties
Yield Uniform Dimensional and Cosmetic Characteristics
Heat Transfer
Heat Dissipation

Protection From

Environment
Thermal Shock
Grease
Salt
Water

Humidity
Gasoline
Diesel Fuel
Vibration
Out-Gassing in Vacuum

Potting/Encapsulation Equipment

Vacuum Chambers
Vacuum Ovens
Curing Ovens

Temperature Controlled Oven
Open Faced Potting Molds
Closed Potting Molds

Encapsulating Materials

Thermoplastic
Thermoset
Epoxies

Silicone Rubber
Polyesters
Other Materials

Temperature Range

105 to 240 °C

Press Size

12 to 30 ton

Testing Equipment

Gauss Meters
Ohm Meters

High Pot Testers
Leak Testes

Testing Capabilities

High Pot Testing
Inductance Testing
Resistance Testing

Leak Testing
Surge Testing

Inspection

Line

Secondary Services

Design and Engineering
In-House Tooling and Machining
Transfer Molding
Injection Molding

Vacuum Impregnation
Encapsulating
Ultrasonic Welding
Assembly

Production Volume

1 to 100,000 units
Prototype

Short Run
Large Scale Production Runs

Additional Information

Industry Focus

Transportation
Power Transmission
Automotive
Metering

Medical
Nuclear Energy
Aircraft / Aviation
Computer

Intended Applications

Aerospace Applications
Automatic Fire Door Closers
Automatic Switches
Circuit Breaker Coils & Solenoids
Current Transformers
Dental Valves
Electric Brakes & Clutches for Construction Equipment
Electronic Locks
Elevator Solenoids & Relays
Fuel Monitors
Fuel Sensors
GPS Sensors
Ground Fault Interrupters
Hand-held Scanner Components
Lighting for Hazardous Areas
Linear Vibrators

Marine Applications
Measuring Equipment
Metering Applications
Microwave Amplifiers
Medical Valves
Position Sensors
Power Transformers
Power Transmission
Printer Components
Precision Instruments
Recreational Vehicles
Security Systems
Sensing Transformers
Tattoo Equipment
Technical Cameras
Time and Productivity Recording

Quality

ISO Methodologies
SPC Techniques
Case Studies

Process Capability Indices
On-Going Improvement

Industry Standards

UL
CSA
VDE

RoHS
Mil-Spec
Nuclear Regulatory Commission (NRC)

File Formats

AutoCAD
MathCAD

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