SQUARE WIRE
The shape of wire for the 21st century!!
For many years, we at Goto relied on round wire in all our products. In the name of innovation this was then replaced in many products by ribbon ( rectangular ) wire. Then, in 1999 as part of our continuous drive for improvement Goto succeded in winding the first square wire coils, a coil type which has many advantages over conventional coils.
Advantages of Square Wire:
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In view of the many advantages that square wire offers over conventional wire, we envisage a big shift to square wire in the near future.
Advantages
An increase in the volumetric occupancy ratio means that the self resonance of the wound coil decreases. Compared to round wire, both ribbon and square wire have a 27% higher voumetric occupancy ratio.
The tendency for current to flow round the surface of a wire at high frequencies is known as the skin effect, and compared with a round wire of same size, the square wire is greatly superior. Comparing with ribbon wire, though the volumetric occupancy ratio is same as the square wire, the square wire is again superior.
*E.g. A 1.0mmø round wire has circumference of 3.14mm. In comparision to this, a square wire of size 1.0 ihas 4 sides of 1mm so a total of 4mm thus 1.27 times superior. Compared with a ribbon wire of 1.0mm x 2.0mm ( total measurement of 4 sides = 6mm ), a square wire has a total measurement of 8mm ( 2pcs of 1mm square wire )
As can be clearly seen from the wire cross sections below, there are many gaps between the windings in a round wire coil, resulting in large heat retention. Compared to this the square wire coil has very few gaps, meaning that it has excellent heat dissipation properties.
When the same DCR as a round wire coil is required, a smaller size square wire should be used. For example, compared with a round wire of 0.45mmø quare wire of size 0.40m x 0.40mm gives the same DCR, meaning that both a decrease in the size of the coil and surounding parts is possible, resulting in a decrease in size and cost of the whole set.
Compared with a coil wound with the same size of round wire, a square wire coil has a 15-20% lower DCR, resulting in a power increase. A lower DCR also results in less heat being produced, meaning that less energy is required, a factor that has obvious environmental benefits in areas such as combatting global warming etc.