Good info. Thanks. I'm gonna book mark that since i don't have a book.
Regarding the window, I guess I had always in the back of my mind decided I would only neatly wind a single layer only which was why the window area thign never occured to me. About the Gauss limits you are recommending, a rule of thumb is to stay less than around 5-10% of the core material's saturation flux density? You're just talking about staying well away from the knee region right? They actually have pretty complete data so it's kind of nice to know exactly how the core saturates. Maybe I'm overlooking something but wouldn't it be okay to operate the maximum at around 50%?
It's gonna be a MPP or Sendust core which saturates at 8000G or 10,000G. THere's still a crapload of room with just 8 turns on a core that size so I could easily fit in more turns which would bring down the flux density quite a bit.
Ahhh...tape...that's how you neatly wind layers on top of each other.
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It might come down to a matter of seeing how much room is on the toroid after I've wound the primary. Of course...litz wire costs money too for that extra winding that's only used half the time.
The stuff that tends to be taken cared of if you just use an IC which is becoming a limiting factor since they have limited gate drive and frequencies that are too high for the power dissipations I require.
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