4. What are the typical thicknesses of aluminum foils used in transformer windings?

The thickness of aluminum foils used in transformer windings can vary depending on the specific requirements of the transformer design, including the voltage rating, current capacity, and space constraints. However, typical thicknesses of aluminum foils used in transformer windings range from around 0.1 mm (100 micrometers) to 0.5 mm (500 micrometers).

For low-voltage transformers or small transformers, thinner aluminum foils may be sufficient to meet the electrical and mechanical requirements. On the other hand, for high-voltage transformers or those designed to handle higher currents, thicker aluminum foils may be necessary to ensure proper performance and reliability.

Transformer manufacturers typically select the appropriate foil thickness based on factors such as the desired electrical resistance, mechanical strength, thermal conductivity, and insulation requirements of the winding. Additionally, considerations such as the number of turns, winding configuration, and space available within the transformer also influence the choice of foil thickness.

Weight comparison - copper wire versus aluminum foil coil transformers

Increased reliability

Reduced size and weight

Higher ambient temperature operating capability

Improved electrical efficiency

Increased electrical stress resistance

Better overall regulation

The use of strip foil conductors in large, high power transformers, to replace the conventional round or rectangular magnet wire, has been commonplace for many years.

In summary, the typical thicknesses of aluminum foils used in transformer windings vary depending on the specific application and design parameters but generally range from 0.1 mm to 0.5 mm.