Low AC resistant foil winding for magnetic coils on gapped cores

1. A method for reducing AC losses in a magnetic coil, comprising:

forming at least one gap in a magnetic core, the gap being centered upon a plane of symmetry normal to an axis defined by a first post and a second post of the magnetic core;

winding one or more pieces of foil to form a foil winding such that

(a) an inner diameter of the winding defines an opening for the first post and the second post, and

(b) successively overlapping cutouts in the one or more pieces of foil form a cavity adjoining the opening and extending in an outboard direction from the opening; and

positioning the foil winding so that the opening is substantially symmetrical with respect to the axis, and the cavity is substantially symmetrical with respect to the plane of symmetry and the gap to reduce the AC losses.

2. The method of claim 1 , the step of winding one or more pieces of foil comprising forming the foil winding from two or more pieces of shaped foil.

3. The method of claim 1 , wherein the magnetic core forms a winding window, and wherein the step of winding one or more pieces of foil comprises forming the foil winding such that a maximum width of the cavity is equal to twice a winding window width when the gap is located on only one side of the winding window.

4. The method of claim 1 , wherein the magnetic core forms a winding window, and wherein the step of winding one or more pieces of foil comprises forming the cavity such that a maximum width of the cavity is equal to a winding window width when the gap is located on both sides of the winding window.

5. The method of claim 1 , the step of winding one or more pieces of foil comprising forming the foil winding to form at least one semicircular shaped cavity.

6. The method of claim 1 , the step of winding one or more pieces of foil comprising constructing the foil winding to form at least one ‘V’ shaped cavity with an open side of the ‘V’ nearest to the gap and a vertex of the ‘V’ further from the gap than the open side.

7. The method of claim 1 , the step of winding one or more pieces of foil to form a foil winding comprising constructing the foil winding to form at least one cavity approximating a semicircular shape.

8. A magnetic coil with reduced AC losses, comprising:

a magnetic core having a first post and a second post extending towards one another along a first axis to define at least one gap between the first post and the second post, the gap being centered upon a plane of symmetry proceeding normal to the first axis; and

a foil winding that circumscribes the first post, the second post and the gap, and forms an inner diameter that defines an opening that is substantially symmetrical with respect to the first axis;

the opening adjoining at least one cavity corresponding to a series of cutouts formed in adjacent layers of the foil winding, the at least one cavity (a) extending in an outboard direction from the first post and the second post, and (b) being substantially symmetrical with respect to the plane of symmetry.

9. The magnetic coil of claim 8 , wherein the magnetic core comprises:

a winding window having a winding window width; and

one or more gaps on one side of the winding window:

wherein a maximum width of each cavity is equal to twice the winding window width.

10. The magnetic coil of claim 8 , wherein the magnetic core comprises:

a winding window having a winding window width; and

the at least one gap is on both sides of the winding window;

wherein a maximum width of each cavity is equal to half of the winding window width.

11. The magnetic coil of claim 8 , wherein the at least one cavity comprises a semicircular shape.

12. The magnetic coil of claim 8 , wherein the at least one cavity comprises a ‘V’ shape with an open side of the ‘V’ nearest to the gap and a vertex of the ‘V’ further from the gap than the open side.

13. The magnetic coil of claim 8 , wherein the at least one cavity comprises an elliptical shape.

14. A method for constructing a foil winding for a magnetic coil, comprising:

forming one or more gaps in a magnetic core, each of the gaps defining a plane of symmetry that is normal to an axis defined by a first post and a second post of the magnetic core; and

forming one or more cavities in the foil winding by (a) forming one or more pieces of foil to form cutouts, and (b) winding the one or more pieces of foil such that each of the cavities forms from overlapping the cutouts as successive layers of the foil form the foil winding, wherein each of the one or more cavities, when integrated with the magnetic core, is adjacent to a corresponding one of the gaps and substantially symmetrical with respect to the plane of symmetry, to reduce an AC loss.

15. A method for constructing a magnetic coil, comprising:

forming a magnetic core having a first post and a second post extending towards one another along a first axis to define at least one gap between the first post and the second post, each such gap defining a plane of symmetry proceeding normal to the first axis;

forming a winding from one or more pieces of foil that form cutouts, such that the winding circumscribes the first post, the second post and the gap to define an opening that is substantially symmetrical with respect to the first axis, the opening including at least one cavity, formed by successive overlap of the cutouts, that extends in an outboard direction from the first post and the second post, the cavity being substantially symmetrical with respect to the plane of symmetry; and

coupling the winding with the magnetic core such that the at least one gap is adjacent to the at least one cavity.