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SMT flat coil planar transformers deliver 500W

Posted: 24 Jul 2013 ?? ?Print Version ?Bookmark and Share

Keywords:Pulse Electronics? flat coil? planar transformers? PCB?

Pulse Electronics Corporation has announced the availability of its latest flat coil surface mount planar transformers. The devices aim to deliver high efficiency power to applications with tight height constraints. The technology uses a copper fill factor that is twice that of a PCB so the direct current resistance (DCR) of the primary winding is reduced by 50 per cent and the power rating is increased by 20 per cent to deliver up to 500 watts of power capability. Replacing the traditional multi-layer PCB winding with a flat coil winding reduces the price by approximately 20 per cent.

Pulse's new standard series of planar transformers measure 21.6x23.4x8.6mm up to 26.7x29.5x11.9mm and are a pin-compatible replacement to existing Pulse multi-layer PCB-based planar transformers. The transformer eliminates the cost and time to fabricate PCBs for new winding arrangements, adding flexibility and speed when prototyping custom variations. Applications include low profile/high efficiency bus converters for distributed power architecture, datacom system cards, industrial controls, and robotics.

"Traditional multi-layer PCB windings with up to 8 consecutive winding layers give rise to high leakage inductance, producing unacceptably high voltage spikes and snubber circuit losses," said Gerard Healy, field application engineer, Pulse Electronics Power Division. "Replacing the multi-layer PCB with a reduced number of flat coil winding layers connected in series provides immediate benefits by reducing the AC proximity effect on copper losses. In addition, more winding segments and selective coupling between simultaneously conducting windings can be implemented to reduce the leakage inductance. This improved interleaving capability has been demonstrated to increase the PSU efficiency on high power systems by 2 per cent."

Planar magnetics have been primarily implemented as a high power (>100W) low profile (Pulse Electronics' new planar series consists of the PH08xx and the PH09xx platforms, which are pin compatible with Pulse's legacy PA08xx and PA09xx series, but with lower DCR.

The planar transformers are RoHS compliant and meet standard EIA481 requirements. Further information regarding the devices can be found here.

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