A manufacturing method for multilayer tube-winding with interleaved primary and secondary windings

In this paper a new multilayer tube-winding method is presented and analyzed. With the proposed winding method it is possible to manufacture transformers with a high level of interleaving using specially shaped flexible conductor sheets. Leakage inductance of the proposed winding method is less than 10% of the value achieved with the traditional wire-wound transformer. An increase of winding losses with traditional wire-wound transformer was 6.2 times higher than with proposed winding across frequency range from 100 kHz to 1.6 MHz.