Modelling Foil Winding Configurations with Low AC and DC Resistance

Significant reductions in winding losses can be achieved by modifying the shape of the cross section of a foil winding. A new method provides improved accuracy for loss calculation in windings with semi-circular cut-outs on gapped cores, as verified by experimental measurements. Optimization using this loss calculation produces designs with up to a factor of two lower losses than either full-width foil windings or litz-wire windings. Foil winding shapes for distributed-gap cores are also introduced and shown to provide reduction in power loss