Conductor Technology:

Winding Window Space (Shared Window)

Window Width Ww (mm)

Window Height Hw (mm)

Number of Turns (N)

Conductor Specification & Insulation

Technology Parameters: Operating in planar-winding mode. The solver automatically sizes conductor cross-section to match current density $J$ and turns $N$.

Electrical & Thermal Parameters

Operating Frequency f (kHz)

RMS Current I_rms (A)

Target Current Density J (A/mm²)

Winding Temperature T_op (°C)

Proposed Spec 375/0.100 (25 × 3 × 5) Standard SKU: LZ-375-0100-SN

Outer Diameter (OD) 2.72 mm Strand wire: ⌀0.100 mm

AC Loss Factor F_R (AC/DC) 1.02× Skin depth δ: 0.240 mm

Copper Loss P_Cu 5.58 W R_AC = 17.2 mΩ (R_DC = 16.8 mΩ)

Conductor Cross-Section & Current Density Adaptive Cross-Section

Window Build Utilization FAIL

107.5 % (≤ 80% Safe)

0 % Warn: 80 Max: 100

Ratio of total winding build thickness W_build to usable window width W_usable.

AC Proximity Factor (F_R) PASS

1.0 × (≤ 1.6 Optimal)

1 × Warn: 1.6 Max: 2.5

AC resistance multiplier due to proximity and skin effect (Dowell).

Current Density (J) PASS

6.1 A/mm² (Target: 6 A/mm²)

0 A/mm² Warn: 6.8999999999999995 Max: 8.100000000000001

Actual RMS current density in bare copper cross-section.

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Winding Health & Diagnostics

1 Notice

ERROR

Window Build Overflow

Winding build thickness (10.75 mm) exceeds usable window depth (10.00 mm). Maximum turns fitting this window: 22.

Recommendation: Increase target current density J to reduce strand count/area, reduce turns N, or select a larger core size (e.g., ETD49, EE55).

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Compare 5 Conductor Technologies on Shared Window

Shared Window Evaluation · Dowell 1D Loss Comparison

Conductor Technology	Proposed Spec	R_DC (mΩ)	F_R (×)	R_AC (mΩ)	Loss P_Cu (W)	Cu Fill (Ku)	Build Util (%)	Window Fit	Action
Litz Wire	375/0.100 (25 × 3 × 5)	15.4	3.92×	60.2	19.50 W	27.2%	83%	⚠ TIGHT
Solid / Multifilar Wire	2filar × ⌀1.37 mm	13.3	29.95×	398.9	129.24 W	27.2%	48%	✓ PASS
Flat / Edgewise Wire	2.97 × 0.99 mm (Edgewise)	14.2	16.72×	236.6	76.65 W	27.2%	62%	✓ PASS
Copper Foil	23.4 mm × 126 µm	13.7	4.94×	67.5	21.87 W	27.2%	54%	✓ PASS
Planar PCB Coil Active	12-Layer Stackup, 3 oz (28.0 mm trace)	16.1	1.48×	23.8	7.70 W	27.2%	95%	⚠ TIGHT	Active

Planar PCB Coil Winding Calculator