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coupling and lowest leakage.   For higher  power applications
(40 watts and above), a split primary “sandwich” construction
is recommended to minimize leakage inductance.  Using a split
primary will in general cut the leakage inductance to half that of
a transformer with a single primary winding.  Split primary
construction for secondary regulated transformers is shown for
the margin wound and triple insulated case in Figures 10A and
10B.  A split winding construction is not recommended for
primary regulated designs, as it will result in poor load regulation.
High power secondary windings consisting of only a few turns
should be spaced across the width of the bobbin window instead
of being bunched together, in order to maximize coupling to the
primary.  Using multiple parallel strands of wire is an  additional
technique of increasing the fill factor and coupling of a winding
with few turns.  In such cases, the wire size may be determined
more by the requirement for a good fill factor rather than the
RMS current rating of the wire.  Where cost permits, using foil
windings is also a good way of increasing coupling, although
this method is usually practical only for low voltage, high
current secondary windings.
and smooths the surface between windings.  The finish wrap of
three layers is more for cosmetic reasons than for safety. There
are no margins and no sleeving.
In the triple insulated primary regulated transformer
(Figure 7D), basic insulation is used between primary layers,
between primary and secondary, and between secondary and
bias.  A three layer outer wrap is required on the outside for
reinforced insulation.  Again, no margins or sleeving are
required.
Reducing Leakage Inductance
The winding order in a transformer has a large effect on the
leakage inductance.  Transformer windings should be arranged
in concentric fashion for minimum leakage inductance.  Offset
or split bobbin construction (shown in Figure 9) should be
avoided, as these techniques will result in high leakage inductance
and unacceptable primary clamp circuit dissipation.
In a multiple output transformer, the secondary with the highest
output power should be placed closest to the primary for the best
Figure 8.  Stacked Secondary Windings for Multiple Outputs.
PI-1798-030896
COMMON 
RETURN
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NP
D2
D1
I2
N2
N1
TOPSwitch
Drain
I1
I2
I1+I2
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V1