CRT Flyback / Line Output Transformer Destructive Teardown

Here’s a small flyback / Line Output Transformer from a portable colour TV set. Usually these transformers are vacuum potted in hard epoxy resin & are impossible to disassemble without anything short of explosives. (There are chemical means of digesting cured epoxies, but none of them are pleasant). This one however, was potted in silicone, so with some digging, the structure of the transformer can be revealed.

The cap was glued on to the casing, but this popped off easily. The top of the core is visible in the silicone potting material.

A small screwdriver was used to remove the potting material, while trying not to damage the winding bobbin & core too badly. The bulge in the casing that I originally thought might house a voltage multiplier turns out to be totally empty. The white plastic bobbin is becoming visible around the core.

After some more digging & a lot of mess later, the entire transformer is revealed. The primary & auxiliary secondaries are visible at the bottom of the transformer, next to the pins. These transformers have multiple windings, as they’re used not only for supplying the final anode voltage of several Kilovolts to the CRT, but many of the other associated voltages, for the heater, grids, focus electrodes, etc. These lower voltage windings are on the same part of the core as the primary.
Above those is the main high voltage secondary winding, which looks to be wound with #38-#40AWG wire (about the thinnest available, at 0.07mm diameter. This is wound in many sections of of a few hundred turns each to increase the insulation resistance to the high voltage. The main anode wire emerges from the top of the bobbin.

Hidden in a recess at the top is the main HV rectifier, which on this small transformer is a single device (it’s probably not internally, most likely a series stack of diodes to get the PIV rating required).