Foil Vs. Wire Windings—How Do They Differ?

by Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Oct 15 2020

Focus:
The two most common conductor shapes for windings are round wire and flat foil. This article assesses the merits of round wire and foil in winding magnetic components. Four comparisons are made to describe the impact of conductor shape on winding loss, with three involving eddy-current resistance. The article begins by comparing foil windings with round-wire and square-wire windings in terms of their effect on packing factor. Next it looks at how wire geometry affects the penetration ratio and winding resistance ratios used in Dowell’s equations, and then goes further to explore 1D and 2D skin resistance effects. Finally, Dowell’s curves are generated to show how winding resistance due to eddy current effects varies with wire thickness and number of layers.

What you’ll learn:

• How to understand how use of foil versus wire windings affects winding resistance in magnetic components

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