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originally posted by: CraftBuilder
a reply to: chr0naut
Thanks for the advice. It’s a transformer, actually an inductor with a sense winding so basically a transformer. Wrapping the windings together as a pair is what I meant in the OP. The math looks good to over 500 turns so I think pairing them up will be fine for now. The biggest problem with hand winding a single wire is that by the time you do a few hundred turns with #44 it's ready to fall apart from all of the flexing.
The application is for a DC-DC converter. A very small one. The input has up to 0.3 volts at 650 micro amps available sporadically. It has to boost it to 3.3 volts and store it until there is enough power to run a microcontroller which performs a function and then sleeps or powers down completely until there is enough charge to do it again. The entire device can’t go over 3.5 grams with peripherals, housing and transport system so I’ve got the DC-DC converter section down to three components. Fortunately, low V and I so very small components. The toroid is the size of the entire rest of the prototype and I'm working to get that down quite a bit. Eventually everything will end up getting die bonded onto a single substrate.