Flexible PCB Windings Size Optimization for Winding AC Resistance Minimization Under the Sinusoidal Voltage Regime

Rafal P. Wojda

doi:10.1109/ACCESS.2025.3589166

Flexible PCB Windings Size Optimization for Winding AC Resistance Minimization Under the Sinusoidal Voltage Regime

Rafal P. Wojda

Grid Systems Hardware

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Abstract

In this paper, optimization of the winding AC resistance of the flexible printed circuit board (FPCB) wire windings is performed. A one-dimensional model of the FPCB winding is introduced and an equation for the FPCB winding AC resistance and its low and medium frequency approximation are derived. The approximate FPCB winding AC resistance equation is used to derive optimum thickness of the FPCB winding conductor thickness at which minimum of winding AC resistance (global optimum) is achieved. The Finite Element Method analysis and experimental verification of derived equations (winding resistance, impedance, power loss, and temperature measurements) is performed in order validate derived model and winding resistance equation.

Original language	English
Pages (from-to)	131030-131041
Number of pages	12
Journal	IEEE Access
Volume	13
DOIs	https://doi.org/10.1109/ACCESS.2025.3589166
State	Published - 2025

Funding

This work was supported by the University Tennessee-Battelle (UT-Battelle), Limited Liability Company (LLC), with U.S. Department of Energy (DOE) under Contract DE-AC05-00OR22725.

Keywords

Eddy currents
flexible printed circuit board
inductors and transformers
magnetic components
winding
winding optimization
winding resistance

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10.1109/ACCESS.2025.3589166

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title = "Flexible PCB Windings Size Optimization for Winding AC Resistance Minimization Under the Sinusoidal Voltage Regime",

abstract = "In this paper, optimization of the winding AC resistance of the flexible printed circuit board (FPCB) wire windings is performed. A one-dimensional model of the FPCB winding is introduced and an equation for the FPCB winding AC resistance and its low and medium frequency approximation are derived. The approximate FPCB winding AC resistance equation is used to derive optimum thickness of the FPCB winding conductor thickness at which minimum of winding AC resistance (global optimum) is achieved. The Finite Element Method analysis and experimental verification of derived equations (winding resistance, impedance, power loss, and temperature measurements) is performed in order validate derived model and winding resistance equation.",

keywords = "Eddy currents, flexible printed circuit board, inductors and transformers, magnetic components, winding, winding optimization, winding resistance",

author = "Wojda, \{Rafal P.\}",

note = "Publisher Copyright: {\textcopyright} 2013 IEEE.",

year = "2025",

doi = "10.1109/ACCESS.2025.3589166",

language = "English",

volume = "13",

pages = "131030--131041",

journal = "IEEE Access",

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T1 - Flexible PCB Windings Size Optimization for Winding AC Resistance Minimization Under the Sinusoidal Voltage Regime

AU - Wojda, Rafal P.

PY - 2025

Y1 - 2025

N2 - In this paper, optimization of the winding AC resistance of the flexible printed circuit board (FPCB) wire windings is performed. A one-dimensional model of the FPCB winding is introduced and an equation for the FPCB winding AC resistance and its low and medium frequency approximation are derived. The approximate FPCB winding AC resistance equation is used to derive optimum thickness of the FPCB winding conductor thickness at which minimum of winding AC resistance (global optimum) is achieved. The Finite Element Method analysis and experimental verification of derived equations (winding resistance, impedance, power loss, and temperature measurements) is performed in order validate derived model and winding resistance equation.

AB - In this paper, optimization of the winding AC resistance of the flexible printed circuit board (FPCB) wire windings is performed. A one-dimensional model of the FPCB winding is introduced and an equation for the FPCB winding AC resistance and its low and medium frequency approximation are derived. The approximate FPCB winding AC resistance equation is used to derive optimum thickness of the FPCB winding conductor thickness at which minimum of winding AC resistance (global optimum) is achieved. The Finite Element Method analysis and experimental verification of derived equations (winding resistance, impedance, power loss, and temperature measurements) is performed in order validate derived model and winding resistance equation.

KW - Eddy currents

KW - flexible printed circuit board

KW - inductors and transformers

KW - magnetic components

KW - winding

KW - winding optimization

KW - winding resistance

UR - https://www.scopus.com/pages/publications/105011067054

U2 - 10.1109/ACCESS.2025.3589166

DO - 10.1109/ACCESS.2025.3589166

M3 - Article

AN - SCOPUS:105011067054

SN - 2169-3536

VL - 13

SP - 131030

EP - 131041

JO - IEEE Access

JF - IEEE Access

ER -

Flexible PCB Windings Size Optimization for Winding AC Resistance Minimization Under the Sinusoidal Voltage Regime

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