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A Revolution in Transformer Design and Manufacture

Design Parameters

The most economical dimensions for a Jencore are similar to Scrapless Laminations. Where the Scrapless Lamination has physical ratios of 3:2:1 (3 = Window Length, 2 = Tongue Width, 1 = Window Width), the Jencore is most economical at a 3:1:3 ratio, which is essentially the same.

To understand these ratios, it is necessary to visualise the Scrapless Lamination cut longitudinally down the centre tongue. This will give two rectangular cores similar to a C Core. The ratio would be 3:1 (3 = Window Length, 1 = Window Width and Leg Width or Build-up in a C Core). The only dimension missing is the Lamination stack (or strip width in a C Core), which is variable. If the stack is fixed to the most economical size, we get a third dimension to our ratio.

When considering the most economical strip width for producing a Jencore, we find that it should equal the window length, hence 3:1:3. This ratio makes an economical transformer of near-cubic shape with high core mass (low loss / kg) and low copper mass (high loss / kg). The low-loss core acts as a heat sink for the heat generated in the copper and there is a large core surface exposed to the copper with short transfer paths.

Note that the Jencore transformer generally has more core mass than a C Core or a Mitred Core, but lower copper mass. This is typical of a good Jencore design where, by increasing the low-loss core mass, it is possible to reduce the high-loss copper mass. The result is a lighter, cheaper and more efficient transformer with better regulation.

Design Criteria of Single and Double (Duo) Distributed Gap Jencores

Single Phase Configuration

Three Phase Configuration

Standard Terminology
Strip Width A
Build-up B
Window Width C
Window Length D
Gap Overlap O
Radius R

Standard Tolerances
±0.3mm on all dimensions

Standard Specifications

	Min	Max
Strip Width	20mm	280mm
Window Width	40mm	Unlimited
Window Height	40mm	Unlimited
Max Core Size	Unlimited

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