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Toroid Inductor Design: Wiring & Winding

When creating custom coil winding, you need to consider more than the intended use of the toroids. It is important to account for core material, packaging, and wire/winding. Below, we want to focus on the importance of custom coil winding and wire. Coil wire and winding is the most important component to determine. Once you plan, picking core packaging and core material becomes much easier.Custom Coil Winding

To get the best custom coil winding, you need to choose wire width, material, coating, winding method, and insulation material.

Copper wire that is round is typically used for inductor winding. Engineers can also choose aluminum and copper that are in square, sheet, and rectangular sizes. It is imperative to keep in mind that wire coating significantly impacts how an inductor will function. Choosing a solderable coating is important for the winding process.

Thermalize is abrasion resistant, and it can withstand temperatures up to 200°C. The material cannot be soldered directly. PTFE (insulated wire) is used to maintain low winding capacitance. You have a wide array of coatings to choose from, so it is important to make the right one.

Coil Winding

Toroidal coil winding, for high and medium frequency applications, needs to establish the distribution of capacitance. Progressive and bank winding methods counter distribution of capacitance. When using foil winding, it can have significant capacitance (from turn to turn).

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