He has also added several new subjects such as rotary transformer design, planar transformer design, and planar construction. W e offer engineered planar magnetics solutions for a broad spectrum of product applications in all major markets. The design of a multilayer planar transformer for a dcdc converter with a resonant. Design of high frequency mhz planar potcore transformer. Transforming the future of power electronics planar.
Aerospace planar transformers for switchmode power. Design, modeling, and analysis of a compact planar. As opposed to conventional wirewoundonabobbin transformers, planar. A planar magnetic is a low profile transformer or inductor utilizing planar windings instead of the traditional windings made of cuwires. Planar magnetic devices offer several advantages over their conventional counterparts. Aerospace planar transformers for switchmode power supplies. Beijing institute of technology, 1995 a thesis submitted in partial fulfillment of the requirements for the degree of master of science in the department of electrical and computer engineering in the college of engineering and computer science. Design, modeling, and analysis of a compact planar transformer article pdf available in ieee transactions on magnetics 4811. The typical construction of a planar transformer is illustrated in figure 2.
Achieving higher ethciency using planar flyback transformers. About standex customer focused engineering solutions. This is achieved by integrating the transformer directly into the pcb. Design guide planar transformers inductors design guide. Topic 4 designing planar magnetics texas instruments. This paper provides a design procedure for small planar transformers for llc converters which builds upon preliminary work in applying design of experiment doe methodology to planar transformer design 9. Design of a planar power transformer for high voltage. Our worldleading design engineering team have developed custom planar transformers from 35w to 50kw in a single transformer component and inductors at 350a, as well as fully developing custom power converters utilising planar magnetics technology. Index terms core loss, dcdc converter, fuel cell, inductor, isolated boost, planar integrated magnetics pim, transformer and winding loss. A compact planar transformer of a new design was analyzed in this paper. Optimal design and tradeoffs analysis of planar transformer in high power dcdc converters ziwei ouyang, student member, ieee, ole c.
Advantages of planar technology there are many advantages of planar magnetic technology over conventional wirewound inductive components. Evaluating planar transformers for dcdc converter designs. High density dcdc power module design with embedded planar transformer wangxin huang, systems engineer, high power controller hpc product line. Ferroxcube 2 exploded view of a planar transformer.
Abstractthe coaxial transformercoupled pushpull circuitry has been used widely in hf and vhf amplifiers for many decades without significant changes in the topology of the transformers. In addition to this, the design guidelines of the signal transformer for. Because of the limited available winding space it is recommended to use the maximum allowed flux densities in planar magnetics. Highfrequency planar transformers are widely used in many electronics converters, such as inverters, drives, power supplies, and resonant converters. The window utilization, ku, comparison of the two different winding techniques is shown in figure 2012. Integrated magnetic design of small planar transformers. In this paper, the most important factors for planar transformer pt design including. Planar transformer catalog 301 east arrow highway suite 108 san dimas, ca 917733364 telephone. You can experiment with the number of turns, dcr and the location of the windings within the assembly interleaving. Embedded planar transformer core selection key steps. Apr 22, 2010 design of a planar power transformer for high voltage, high frequency use abstract. Pdf planar magnetics design for lowvoltage dcdc converters.
Integrated magnetic design of small planar transformers for. This paper discusses the design and use of lowtemperature 850c to 950c cofired ceramic ltcc planar magnetic flyback transformers for applications that require conversion of a low voltage to high voltage 100v with significant volumetric. Planar magnetics are very well suited for design of high performance switchmode power. Andersen member, ieee abstract the trend toward high power density, high operating frequency, and low profile in power converters has. A highvoltage 15 kv power transformer using multilayer printed circuit board mlpcb technology is presented for applications in switchedmode power supplies, whose output power is 4. Custom design of all types of planar inductors and transformers for highfrequency dcdc converters power supplies with input voltage from 0v to 150v and output voltage from 0.
Layer design 14 design of planar power transformers. Flyback continuous mode planar transformer design tutorial an industry session at apec 2020 jim marinos payton america inc. Strategies for optimizing planar design are presented, and illustrated with design examples. Xun li professor, department of electrical and computer engineering number of pages. Standard part numbers are available of the shelf, and customized quickturn prototypes are available in a.
Ferroxcube 3 planar transformers can be constructed as stand alone components, with a stacked layer design or a small. However, at high frequency, the planar transformer ac losses become significant due to the proximity and skin effects. Nov 03, 2014 optimized planar core design traditionally, planar cores were designed with large apertures to facilitate the multiple interconnects between windings layers as well as the termination of the windings to the main pcb. We changed the voltage ratio by using different seriesparallel connections. Inhouse the design engineer can adapt the different combinations of serial and parallel configurations of the windings to give a substantial number of ratio and current possibilities via the supplied software. Design, modeling and simulation of planar waveguide time domain optical fourier transformer author. Ecores are commonly used to wedge pcb winding or copper foil winding in a planar transformer 57. Na5738dl smt planar transformer for texas instruments ucc2897.
Design of a planar power transformer for high voltage, high. The transformer was analyzed without the core and with the core. Planar magnetics have become very common in dcdc converters and other power conversion devices. View the kit manual this is the kit used by coilcraft designers to provide fast turnaround of planar transformer samples. Designing a planar transformer and using the pc winding technique, reduces the window utilization factor even further. The devices unique design can be optimized for customerspecific switching frequencies, input and output voltages, and current levels. High density dcdc power module design with embedded planar. Planar transformers can be used in forward, pushpull, and full bridge half bridge topologies. The transformer is one of the fi rst critical components in the.
Introduction ne of the more interesting magnetic design techniques in practice today by power supply engineers is the blending or mixing of transformer and. Developed for ti ucc2897 active clamp pmp7376 reference design designed for 52 60 vdc input. Pdf design of high frequency mhz planar potcore transformer. Optimal design and tradeoffs analysis for planar transformer in. Wire effective resistivity cm total rms winding current, ref to pri itot a desired turns ratios n2n1, n3n1, etc.
Designing with the pla51 planar transformer for enhanced. The hybrid planar transformer series is available in surfacemount and throughhole configurations. High density dcdc power module design with embedded. High efficiency low losses, ultra compact, lowprofile.
This paper discusses the magnetic fields within the planar structure and their effects on the distribution of high frequency currents in the windings. Abstracta new trend in power converters is to design a planar transformer that aims for low profile. Planar means to control leakage inductances between inductive windings are also presented for control and reduction of ac ripple current magnitudes. Designing with the pla51 planar transformer for enhanced power density and efficiency application note. For lowpowerlevel application, it is possible to use core. The design is based on a discontinuous conduction mode dcm flyback converter topology. In addition, he provides realworld, stepbystep design examples. When it comes to standex electronics custom transformers custom is standard. Transformers application note designing with the pla51 planar transformer for enhanced power density and efficiency. Semantic scholar extracted view of planar magnetics design for lowvoltage dcdc converters by shangyang xiao. The design of a multilayer planar transformer for a dcdc converter with a resonant inverter magdalena puskarczyk, radoslaw jez abb corporate research center, a starowislna st.
The designs in that sand report were all based on a ferrite tapedielectric paste system originally developed by nascentechnoloy, inc, who collaborated in the design and manufacturing of the planar ltcc flyback converters. Comparisonof planar transformersandnewlydesignedwcmtransformersforelectricvehicles kevinbai,directorofadvancedpowerelectronicslab,departmentof. When designing planar transformer pc windings, designers use the same technology used by the printed, circuit board designers, and that is the current rating for a given voltage drop and temperature rise. May 29, 2015 standexmeder electronics is a global leader in the design, development, and manufacturing of standard and custom planar transformer solutions.
Design of planar power transformers elna magnetics. Matte tin over nickel over brass terminations pricing pdf data. The tida00688 reference design provides isolated 15v and 5v outputs in a very thin form factor with only 2. The design process of the highfrequency planar transformer is very complicated because of. The author covers magnetic design theory with all of the relevant formulas along with complete information on magnetic materials and core characteristics.
Achieving higher ethciency using planar flyback transformers for high voltage acdc converters white paper 0817 eic1743 the bourns planar flyback transformer was tested on an acdc adaptor shown in figure 4. Magnetics designer is a standalone software program for windows that designs all types of layer and sectorsplit bobbin wound transformers and inductors, and generates a corresponding spice model. Optimal design and tradeoffs analysis for planar transformer. A compact planar transformer with an improved winding configuration has been designed and fabricated. However, they dont perform as well as conventional transformers when used in a flyback topology, and since they are relatively uncommon, finding one that meets your. Planar ltcc transformers for high voltage flyback converters. Planer transformar mina has been designing, developing, manufacturing and marketing custom planar transformers since 1992. Planar transformers are devices used to exact standards with precise electrical characteristics such as capacitance, output, and aspect ratio. Topologies include full bridge, half bridge, full bridge zvs, pushpull. Edn designing a highefficiency planar transformer for 250.
Planar inductors are low profile and have exceptional current handing. As opposed to conventional wirewoundonabobbin transformers, planar transformers usually contain winding turns made of thin copper sheets riveted together at the ends of turns in the case of high current windings, or. Measurements on planar e core transformers under operating conditions with windings in multilayer pcbs show that the thermal resistance is substantially lower. Using ferritic core, the inductance was increased for 22%. Using planar transformers dcdc converter designs digikey.
Standard transformer typical planar transformer copper area window area, wa ku 0. It does not offer information regarding design criteria. Design guide planar transformers inductors design guide planar transformers inductors bus bar termination customize beyond these examples. Except for the wall warts, magnetics in every modern converter i either acquired for my projects or reverse engineered to see how it is made and works, had this type. Pdf design, modeling, and analysis of a compact planar. Design, modeling, and analysis of a compact planar transformer. With the assumption that half of the total transformer. However, they dont perform as well as conventional transformers when used in a flyback topology, and since they are relatively uncommon, finding one that meets your specifications can be difficult. In general, there is not a huge difference between implementing a planar transformer versus a comparable conventional transformer in a dcdc converter design. Magnetics designer produces a complete transformer or inductor design based upon electrical specifications, including a winding sheet report and a spicecompatible model with parasitics. This relation can be used to estimate the temperature rise of the transformer as a function of flux density in the core. Terratel offers planar transformer or other electronic equipment with their use design services.
Applying the basic principles of magnetic field behavior discussed in earlier seminars to planar magnetic structures enables us to optimize the design and predict. In this paper the most important factors for planar transformer pt design including. Comparison with the conventional transformer shows that successful operation is possible with the low profile core. Na5738dl smt planar transformer for ti ucc2897 pmp7376. Djuric et al design, modeling, and analysis of a compact planar transformer 47 fig. High frequency mhz planar transformers for next generation. An improved transformer for llc resonant inverter for. Title analysis and design of high frequency gapped. Planar transformer designers handle the current density in a different way. Pdf a novel design in the use of planar transformers for. Planar transformers are high frequency transformers used in isolated switchmode power supplies operating at high frequency. Meandertype design was engraved over the surface of a planar ferrite core, so that the.
Calculating performance of planar magnetics 2 the transformer consisted of four windings having eight layers and 38 turns total. Click here for a summary of our newest planar transformers and a detailed description for determining losses and overall efficiencies. Planar magnetics design for lowvoltage dcdc converters. The design of a multilayer planar transformer for a dcdc.
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