WIRES COMPENDIUM FOR MAGNETIC ELEMENTS DESIGN
In this app-note the different magnet wires used by FRENETIC in its design are listed, detailing each of the pros and contras entailed by their use.

ROUND WIRE

Most commonly used wire, made of a round conducting section covered by an insulation layer. 

PROS: 

  •   Easiness of use
  •   Low cost

CONTRAS:

  •   Bad AC resistance at high frequency
  •   Bad compacity


SQUARE WIRE

Similar to round, but with a square section.

PROS: 

  •   Good compacity
  •   Large conducting section

CONTRAS:

  •   Bad AC resistance at high frequency
  •   High cost


LITZ WIRE

Wire made of many thin wire strands, individually insulated and woven together in prescribed patterns.

PROS: 

  •   Good AC resistance at high frequency
  •   Easiness of use

CONTRAS:

  •   Lowest compacity
  •   High cost

RECTANGULAR WIRE

Similar to round, but with a form factor that can optimize better winding windows.

PROS: 

  •   Best compacity in some cases
  •   Large conducting section

CONTRAS:

  •   Bad AC resistance at high frequency
  •   Can be difficult to wind

PLANAR WIRE

Wire printed directly on a PCB, using external and internal layers, when a low profile magnetic is needed.

PROS: 

  •   High repeatibility
  •   Good AC resistance at high frequency

CONTRAS:

  •   High prototyping cost
  •   Low conducting section

FOIL WIRE

Wire made of thin insulated sheets, that can be cut to height needed in each design.

PROS: 

  •   Best compacity
  •   Good AC resistance at high frequency

CONTRAS:

  •   High cost
  •   Bad compacity

CONCLUSIONS

There are billions of possible combinations along the path towards designing the optimum magnetic element. When, additionally, different types of wires are introduced to the equation, the complexity of the problem can grow mindnumbingly large; especially because the usage boundaries and their trade-offs are not always clear.

That's one of the reasons we have created Frenetic, where our AI is able to navigate all the variables and give our customers the optimum design, with optimum winding, for their power needs.

Magnetic components are the actual bottleneck for improving the power density in power conversion. For that reason in SPC we have created Frenetic. Frenetic is able to provide a working design without iterations needed in less than a week.













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