Uncovering how thin steel plates revolutionize transformer core performance

Using thin steel plates to manufacture Transformer Cores can effectively reduce unnecessary power losses. In a typical transformer structure, the core is made of thin silicon steel sheetslaminated together. These silicon steel sheets are carefully stacked to form the necessary magnetic path while minimizing magnetic losses. Since silicon steel has a high resistivity, the use of thin sheet stacking can significantly reduce eddy current losses. These silicon steel sheets are usually between 0.25mm and 0.5mm thick and are insulated between each sheet by a thin coating of paint or oxide layer to prevent current from passing directly through the stack.

The structure of the transformer is usually named according to the configuration of the windings and the core. The two common basic designs are the closed core (iron core type) transformer and the shell type transformer. In a closed core transformer, the windings are wound around the outer annular portion of the core. In a shell type transformer, the winding passes through the core, which surrounds the winding like a shell. In both designs, the magnetic flux connecting the windings travels primarily inside the core, reducing flux losses through the air.

In an iron core type transformer, half of each winding is wound around each leg (or limb) of the core. The core design of the shell-type transformer helps to overcome the leakage magnetic problem because its windings are all wound on the core and the core has two outer limbs, which provides two closed magnetic paths for the magnetic flux, allowing the magnetic flux to flow on the outside of the left and right sides before returning to the coil, thereby improving the efficiency of the transformer.