Split Cores for Toroidal Transformers

It would be the advantage that a gap presents to magnetic cores of any shape. You can have a much improved stability of the value of the inductance over a wide range of temperatures plus a choice of different currrents before saturating the core.

It is amazing that you want to do the spliting of the toroid before knowing what the results would be.

Hi, We are undertaking this as a project for easy sourcing. Currently I am working on the project with different tests to ensure the results and the answers provided here can also be verified.

Thanks for the inputs.

I have misread your posting. It seems that you want to keep the toroid, and just to slice it, to obtain two or three "toroids". No gap. In this case, you reduce the cross section, so less power for one section. It is a trade between advantages of cooling the whole assembly (obtained by slicing the doughnut), loss of power you can get from them, and price.

Hi,

Thanks for the reply

Let me make it more clear. presently the toroid what we are winding is having 60 mm height. The proposed change would be 3 no.s of 20 mm height cores joined mechanically. The same design of primary & secondary would be wound on this mechanically joined cores. This is being studied for advantage/disadvantage. Hope now I have made it more clear.

Probably not. You haven't provided enough information for an absolute answer; what sort of material, what flux level, what frequency?

The flux density would be less than 1.5 T. & frequency is 60 HZ. Material is 0.27 mm M4.

Thanks for the reply. You'll get a slightly larger mean length of turn for a given cross-section. Otherwise, you should see no difference.

I have scrapped out old toroid core transformers and inductors before that had been made by stacking multiple smaller toroids together so its apparently not an uncommon design.

I suspect it follows the concept of just increasing the core cross section area for higher power handling capacity. From the manufacturing standpoints it may have been cheaper or easier to make them that way.

As Indel quoted have done any work? You see any advantage? price, less losses, manufacturability, etc?

Hi . THis is the proto testing we are planning. It will be good for me to know, what to expect from this test in advance.

Raju,

My preference for ease of manufacturing of general use tranformers is to use a core made of separate parts and drop ready-made windings into them. They can be tested and before permanent bonding.

I have used these products for 60Hz 400Hz input systems and 50kHz switching power supplies.

Kuduk