When winding toroidal coils, quite often unique insulation requirements surface. This is especially true in the larger custom wound core type toroidal or ring coils. See Figure 1.rnThe initial insulation requirement in special size units is to insulate the core in such a way as to prevent shorting or grounding of the windings. Many toroidal cores of soft magnetic lamination steel, when flat wound, have very sharp comers. See Figure 2. These knife-like comers tend to cut into the insulation making it increasingly difficult to provide adequate protection. The strong winding tension causes changing vector forces which can increase the tendency to penetrate insulation at the corners.
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