Is high frequency involved?
Excerpt from ePanorama.net
Skin effect
Skin effect is an effect that the electricity in high frequencies does not use the whole conductor area. High frequencies tend to use only the outer parts of the conductor. The higher the frequency, the less of the wire diameter is used and higher the losses. Sin effect must be taken care in high frequency coil designs.
The frequency dependency of the resistance of a cylindrical conductor can be calculated by the following formula, which is surely valid for high frequencies and radii of approx. 50 um:
R(f) = R(DC)* (1 + 1/3 * x^4) with x = Radius/2*sqrt(pi*frequency*permeability*conductivity)
The "formula" for skin effect is the same whether the conductor is rectangular or cylindrical. That is why the same value of "radius" used in wire size in a switch mode transformer is used to determine half the thickness of a flat foil conductor in the case of foil-wound secondary’s.
An approximate equation for the resistance ratio for rectangular conductors (from Terman) is:
rho = 1/(((8PI * f)/(Rdc * 10^9))^0.5)
Skin depth is not an absolute, but only the depth where current through the wire or foil has fallen to a specific proportion of the current at the surface. In fact, current falls off exponentially as you move inward from the surface. The depth of the "skin" is also influenced by proximity to nearby conductors (such as in a transformer) so is itself not absolute. Also the formula has to be modified if you use wire that is ferromagnetic (iron for example).
In addition to skin effect a lot of engineers doing their own magnetic design don't consider the 'proximity effect' which 'crowds' the current to one side of the conductor and increases losses. This condition is worst in thick multi-layer windings. Fortunately, many of the new transformer shapes have a long and skinny window - good for low leakage L and low proximity effect losses.