Toroidal coils certainly differ from normal coils, most visibly in their shape. Normal coils may be cubic or rectangular in shape, with the wire wrapped around a bobbin, with a set of cores fitted through the centre and around the outside of the bobbin. But, toroidal coils have a ring or donut shape, which is due to the different shape of the core material. In a toroid, a donut shaped core is used, and the wire is repeatedly taken through the central hole, and wrapped back around the outside. Because of this different shape of the coil, a specialized manufacturing process if required to manufactured toroidal coils. They do not have a standard mounting, like in the case of normal coils. Instead, their connections tend to be flying leads. although, smaller coils can be mounted on bases that allow easy insertion into PCBs.
Does the special shape bring any advantages?
- The ring shape of toroidal coils minimizes the escape of magnetic flux. The core is a closed loop, with no ends or corners from where the flux can escape. This means that there are reduced losses, which lead to greater efficiency and lesser electromagnetic interference.
- Moreover, the windings can be distributed around the whole core, which gives better utilization of the core material, and better coupling between separate windings. This better utilization and better coupling ultimately result in better efficiency.
- The closed loop of a toroidal coil results in a higher magnetic field, which leads to higher inductance and Q factor.
- With all of the above, the improved efficiency of a toroidal coil results in more power being obtained, which helps it to be used effectively in mains power transformer applications.
Where are toroidal coils used?
One of the major applications of toroidal coils is in the audio industry. The improved efficiency and working of toroidal coils with reduced losses results in reduced distortion and fringing effects, which thus helps to produce a cleaner sound. This particular benefit has proven toroidal coils to become a great advantage to the audio industry. Other industries that also make effective use of toroidal cores include telecommunication, ballasts, EMI filters, and medical equipment.
Let’s learn about toroidal chokes too!
There are two common types of toroidal chokes, namely common mode chokes and differential mode chokes. Both these chokes are used for blocking or choking unwanted frequencies or interference. Common mode chokes use the toroidal shape by putting two windings on one core, the windings being used to cancel out the interference, because they are wound in different directions. These windings provide suppression without saturation.
Where to get your toroids?
Miracle Electronics is one of the best toroidal transformer manufacturers in India where you can have your toroids made. You can have special customized transformers made, and ascertain that they are the ideal choice for your utility, with their superior wires, varnishing, and connection terminators, which provide durability, efficiency, and minimal temperature rise. All the transformers available here are RoHS and REACH compliant; thus ensuring the best quality.