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Registered Member #1819
Joined: Thu Nov 20 2008, 04:05PM
Location:
Posts: 137
I'm currently in the process of winding a high frequency push-pull transformer on a FT-240-77 core. It operates at 50kHz, requires a minimum 1085W power output, and has a 1:2 turns ratio with primary turns of 4+4. The 12V input voltage results in a total primary current of 91.25A at full power.
In order to sustain this current without dissipating over 10W as copper losses, I decided to have 20 individual strands of 24 AWG wire in parallel for the whole primary. Of course, I knew 20 strands of this wire twisted together would be impractical, so I've narrowed it down to two options: 4 strands of 5 24AWG strand litz wire, or each wire 20-filar (?) on the core.
Is there any serious benefit or disadvantage for the "20-filar" wound transformer? This is a lot easier to wind that the 4 strands of the 5-strand litz wire, so I need to know of any serious defects in this method (such as excessive proximity effect losses) before I wind it.
Registered Member #56
Joined: Thu Feb 09 2006, 05:02AM
Location: Southern Califorina, USA
Posts: 2445
Why not just use some 'real' litz wire. I have some a spool ~10awg wire (210/36awg) that I would be willing to cut you a piece off of. Although it it at home so I couldn't ship it until march.
In any case, I do not see any serious drawbacks to the 20-filar transformer, if anything it seems like if you wound it carefully it would give a very good fill factor for the apparent size of the wire. Just try to keep the conductors somewhat grouped together (ie, don't just random wind 20 strips of wire on the core) or you might run into excessive heating on individual strands (amonother other nasties)
Registered Member #347
Joined: Sat Mar 25 2006, 08:26AM
Location: Vancouver, Canada
Posts: 106
Don't use wire at that high a current, use copper foil. Perhaps something like 2 * 0.3mm thick layers of copper foil in parallel for low resistance, sort of a "litz foil".
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Litz Wire vs. Multifilar Winding
