In alternating current applications, the “skin effect” can significantly contribute to unwanted heat. Further, heated air that may be flowing over one part of the coiled wire may flow over another part of the coil instead of away from the coil. When layers of conductors are wound over one another, they can’t cool as efficiently because heat from one part of the wire will radiate to other parts of the wire and the winding components, rather than dissipate primarily into the open air. A coil packs a lot of copper into a confined space. However, natural resistance isn’t the only reason coiled wire heats up. The amount of heat produced is in direct relation to the wire’s natural resistance. Increasing the wire gauge reduces resistance and resulting heating, but also increases the cost, size and weight of the coil. Because coils require long lengths of wire, heat produced due to resistance can be a significant factor. Wire heats up when an electrical current passes through it due to its natural resistance. New England Wire Technologies has developed a technology that saves time, money and gives design engineers and manufacturers proven, UL-listed solutions for building safer wire coils. Because they are not “perfect,” they suffer losses that show up as heat. Motors, induction heaters, transformers and other devices with wound wire coils pose a problem to designers.
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