The design of barrel-wound foil windings with multiple layers interchanged to balance layer currents

This work investigates the performance of multilayer foil windings in which the layers are interchanged to balance the flux linked by each layer and thus the current is shared equally between layers. Prototype transformers were built to confirm how much of the theoretical loss reduction is achievable in practice. The accuracy of the method to determine the location of the interchange is improved by considering individual turn lengths. In addition, the method is extended to any number of layers and several winding configurations. A discussion of the construction and termination of these windings is included as they greatly affect a component's performance.