Packing out a bobbin with nylon "wire" to reduce fringing effect heating on transformer coils
Posted by: treez
on
Hi,
I notice power.com DER's often use custom bought nylon served Litz wire for eg PFC inductors, or LLC transformers, Two transistor Fwd transformers etc.
This is expensive and hard to source. Better to use TEX-ELZ would you agree?
To avoid heating in coil due to closeness to the centre leg gap in a ferrite core, simply pack out the bobbin with nylon fishing line...as attached.
What are your thoughts on this?
It means you can use TEX-ELZ instead of that "40 strand AWG28 Litz", which is expensive
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This might work if you are willing to accept a lot less room for actual wire on the bobbin as a consequence and are OK with fiddly time extensive optimization in the lab, documenting the exact procedure, getting an XFMR vendor to buy into it, and paying for an extra manual labor step in construction. With served Litz, you just just wind in one step and are done. People time in manufacturing is expensive. Also, if you are filling up part of your winding window with nylon, you may have to use a larger core so that you have room for the required amount of copper.