What are the does and donts of winding an inductor yourself? I am attempting to make a coupled inductor on an "e core" (N48 core). I have calculated the winding parameters and I discovered that I need about 4 turns of 2mm (diameter) wire in the primary and 40 turns of 0.6mm wire in the secondary. I used scotch cast resin to coat the wire. However, I'm not very confident with the winding procedure. I've been searching youtube for videos but none are related to the problem at hand. I would appreciate some advice or links to hidden "how to" videos. Attached is an image of my attempted design.

 

What is the purpose of the inductor? Do you intend to use the other half of the core?

The coupling between those windings will be quite poor since you have essentially an open magnetic path with the windings widely separated.

 

What is the purpose of the inductor? Do you intend to use the other half of the core?

The coupling between those windings will be quite poor since you have essentially an open magnetic path with the windings widely separated.

I want to use for a boost converter. Need the high turns ratio to "step up" the voltage. What can I do to improve coupling?

 

Do you mean a flyback converter? It would be very unusual to use a coupled inductor in a boost converter.

 

Use two "E" cores and put both winding on the centre part of the "E". Doing it this way you will have a closed magnetic circuit and the two coils will be tightly coupled.

Les.

 

Use two "E" cores and put both winding on the centre part of the "E". Doing it this way you will have a closed magnetic circuit and the two coils will be tightly coupled.

Les.

Thank you. Are there any other pointers you would like to share?

 

Do you mean a flyback converter? It would be very unusual to use a coupled inductor in a boost converter.

An interleaved boost

 

Wind on the center leg of the core, not the outside "arms".

One thing that gets past beginners is the magnetizing current. The lower the inductance, the higher the magnetizing current. This adds to the current for the load by the square room of the sum of the squares. If you try to increase inductance by adding another E core you will make what you might call a magnetic short circuit which will prevent the two windings from coupling to each other.

Wind both windings around the center leg, then you can use an E-E or E-I configuration to get both good coupling and lower magnetizing current.

If you can find a bobbin for that core it will make your life a lot easier.