The choice between foil and wire windings depends on the specific application requirements, as each offers distinct advantages.
Foil windings, made from a thin, wide aluminum or copper sheet, provide excellent thermal dissipation and a high fill factor, leading to robust mechanical stability and efficient cooling. They are ideal for high-current, low-voltage applications due to their large cross-sectional area, which minimizes eddy current losses and offers inherent strength. However, they are less flexible for complex designs and typically more expensive.
Wire windings, using round or rectangular conductors, offer greater design flexibility and are cost-effective for mass production. They are suitable for high-voltage applications due to better insulation handling and easier tapping. Yet, they have a lower fill factor, potentially higher losses, and may require more complex cooling solutions.
In summary, foil windings excel in high-current, low-voltage scenarios with better thermal performance, while wire windings are preferred for high-voltage, flexible designs and cost-sensitive projects.
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