Himag 2016 brochure

CONTENTS Market Sectors Company Profile Planar Technology Product Range Overview

2/3 4 5 6/7

Size 140 MAX 1kW Size 195 MAX 1.5kW Size 225 MAX 2kW Size 230 MAX 2kW Size 350 MAX 6.5kW Size 500 MAX 10kW Size 510 MAX 10kW Size 540 MAX 15kW Size 1080 MAX 30kW Size 1200 MAX 50kW Size 2400 MAX 80kW Size 3600 MAX 120kW

8/9 10/11 12/13 14/15 16/17 18/19 20/21 22/23 24/25 26/27 28/29 30/31

32/33 Custom Design Thermal Handling/Cooling 34 35 Terminations 36 Conventional Parts 37 Other Products Contact Us

38

MARKET SECTORS

Defence

2

3

Automotive

Traction

Aviation

Industrial

Medical

Communication

COMPANY PROFILE

4

Himag Planar possess over two decades of experience in the field of planar transformers with a long history in inverter technology and PCB design. Himag Planar has become the global market leader in the development of planar transformer technology, design and manufacture. We have as a group to date manufactured million’s of planar transformers, including thousands of custom planar transformer designs.

As part of a wider group we are a truly global company with manufacturing & engineering design facilities in Israel, USA and Asia as well as the UK. We manufacture from one off bespoke quick turnaround prototypes through to volume production both in the UK and overseas. Our structure and resources cater for all of our customer requirements.

In the UK we are housed in our own 7000 square foot facility which we are currently updating ensuring we keep pace with increasing production as Planar technology becomes the standard for high frequency electronics.

5

PLANAR TECHNOLOGY

Planar Transformers Planar Transformers are suited to high frequency switching applications, with a typical switching frequency of 20kHz – 5MHz. The fundamental difference between planar transformers and traditional wire-wound transformers is the use of flat copper conductors, resulting in higher efficiency due to the ability to interleave windings and to design the conductor for skin effect.

Planar Windings are constructed using flat copper layers (‘lead-frames’) or printed circuit boards (PCBs) to form a laminate style winding construction, which are then sandwiched between small, light-weight planar cores.

The result is a compact, high power density planar transformer that is typically smaller, lighter, and more efficient than its conventional wire-wound equivalent.

Advantages • High Efficiency (>99%)

• High Efficiency Cooling

• Low profile

• Multiple Topologies

• Lightweight (5g per 100W)

• Multiple Winding Options

• Low Leakage Inductance

• Dimensional Accuracy

• Repeatability (Controlled Parasitics)

• 4kV Isolation, typical

• Customised Terminations

• Reduced EMI

PRODUCT RANGE OVERVIEW

6

PRODUCT RANGE OVERVIEW

7 Inductor Applications

Transformers

Output Power

Frequency

Input/Output Voltage

Output Current

Page No.

Size: 140

1kW MAX

≥ 3MHz MAX

≥ 500V MAX

≥ 100A MAX

8/9

Size: 195

1.5kW MAX

≥ 3MHz MAX

≥ 500V MAX

≥ 120A MAX

10/11

Size: 225

2kW MAX

≥ 3MHz MAX

≥ 600V MAX

≥ 150A MAX

12/13

Size: 225

Size: 230

2kW MAX

≥ 3MHz MAX

≥ 500V MAX

≥ 200A MAX

14/15

Size: 230

Size: 350

6.5kW MAX

≥ 3MHz MAX

≥ 750V MAX

≥ 300A MAX

16/17

Size: 350

Size: 500

10kW MAX

≥ 2MHz MAX

≥ 1000V MAX

≥ 500A MAX

18/19

Size: 510

10kW MAX

≥ 2MHz MAX

≥ 1000V MAX

≥ 300A MAX

20/21

Size: 540

15kW MAX

≥ 1MHz MAX

≥ 1000V MAX

≥ 750A MAX

22/23

Size: 1080

30kW MAX

≥ 1MHz MAX

≥ 1000V MAX

≥ 1000A MAX

24/25

Size: 1080

Size: 1200

50kW MAX

≥ 500kHz MAX

≥ 1000V MAX

≥ 1200A MAX

26/27

Size: 1200

Size: 2400

80kW MAX

≥ 500kHz MAX

≥ 1000V MAX

≥ 1200A MAX

28/29

Size: 3600

120kW MAX

≥ 500kHz MAX

≥ 1000V MAX

≥ 1200A MAX

30/31

140

225 195

350 230

500

510

540

1200 3600 1080 2400

Size: 140

1x10 3

Typical AL (nH/ t 2)

Size: 195

Size: 500 Size: 510 Size: 540

Size: 2400 100

10

100

Ampere Turns

1x10 3

1x10 4

Size: 3600

TRANSFORMERS & INDUCTORS

8

Transformer Parameters

Transformer Specification Example

1kW

40G

2.5kV

Voltage

Current

500V

50A

Topologies • Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck • Flyback

Inductor Application 1x10

Transformer Technical Information

SIZE 140

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary

100

Primary - Core

4kVrms 2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

20kHz-3MHz

Total Output Power Topology PSU Output DC Voltage & Current Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Cooling Ambient Temperature Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

240W Full Bridge 12Vdc @ 20Adc (max) 9μH 25% 20A rms 20A rms 125kHz 9V 16V 1:2(+2 bias on primary & secondary sides) Heatsink -20oC to +80oC 1000Vrms 500Vrms 500Vrms EN60950

1

1

Bias Bias Bias 2

10

100

1x10

Ampere Turns

3

1x10

4

40 40

32,1

ER32

40

12

Weight

2197-01

32,1

Power

Dimension Diagram

32 32,1

Core

Dielectric Isolation

40

ER32 (Size ER32140) (Size 140)

12 12

SIZE 140

TRANSFORMERS & INDUCTORS

12

1kW Max Power

9

2 1 3

B ias Bias

9

Bias

9

8

3

7

Primary Primary

B4ias Primary

Secondary Secondary 6

Bias Secondary 5

8 9 7 6

21

TRANSFORMERS & INDUCTORS

10

Transformer Parameters

1.5kW Max Power

SIZE 195

11

TRANSFORMERS & INDUCTORS

Transformer Specification Example

E38 (Size 195)

8003

Dimension Diagram E38 (Size 195)

8003 60

Voltage

Current

E38

1.5kW

60G

2.5kV

500V

75A

Topologies • Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck • Flyback

Inductor Application 1x10

Transformer Technical Information

SIZE 195

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary

100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

20kHz-3MHz

Total Output Power Topology PSU Output DC Voltage & Current Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Nominal Bus Voltage Turns Ratio Primary to Secondary Cooling Ambient Temperature Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

830W Current Doubler 29.5Vdc @ 28Adc (max) 4.8μH 25% 40A rms 13.3A rms 250kHz 22V

60 60

38

Dielectric Isolation

38 38

Weight

1:3 Coldplate @ 100oC 16 16

Power

16

Core

2000Vrms 2000Vrms 2000Vrms EN60950 Primary

Secondary

Transformer Parameters

2kW Max Power

SIZE 225

Transformer Specification Example

Core

Power

Weight

Dielectric Isolation

Voltage

Current

ER41

2kW

100G

2.5kV

600V

75A

Topologies • Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck • Flyback

Inductor Application 1x10

Transformer Technical Information

SIZE 225

3

Isolation Voltage: Primary - Secondary

Typical AL (nH/ t 2) 100

10

100

1x10

Ampere Turns

3

13

ER41 ER41(Size (Size225) 225) ER41 (Size 225)

1x10

4

4kVrms

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

20kHz-3MHz

2044 2044 2044

Dimension Diagram 45

Total Output Power Topology PSU Output DC Voltage and Current Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Max Duty Cycle Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Total Transformer Losses Cooling Ambient Temperature Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

2kW Full Bridge ZVT 255Vdc @ 8Adc, 420Vdc @ 4.75Adc 1.0mH 25% 7.7A rms (max) 5.5A rms (max) 250kHz 0.41 375V 480V 10:14 14W (max) Liquid Cooled Baseplate -40oC to +105oC 2700Vdc 2700Vdc 2700Vdc EN60950

41

12

TRANSFORMERS & INDUCTORS

16

TRANSFORMERS & INDUCTORS

111

666

PP rim ary P rim ary Primary rim ary

333

555SS econdary S econdary Secondary econdary

444

TRANSFORMERS & INDUCTORS

14

Transformer Parameters

2kW Max Power

SIZE 230

15

TRANSFORMERS & INDUCTORS E43 (Size 230)

Transformer Specification Example

80171

E43 E43(Size (Size230) 230)

Dimension Diagram

E43 (Size 230)

Dielectric Isolation

Voltage

Current

E43

2kW

100G

2.5kV

500V

75A

Topologies • Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck • Flyback

Inductor Application 1x10

Transformer Technical Information

SIZE 230

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies 100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Total Output Power Topology PSU Output DC Voltage & Current Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Cooling Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core

1kW Half Bridge 400V @ 2.5 max 9.7μH 25% (provisional) 87A rms 2.4A rms 100kHz 24V 48V 1:36 Heatsink 4000Vrms 2500Vrms 2500Vrms

73 73

43 43

Weight

24 2424 24

Power

24

Core

43 43 43

7373

80171 80171 73

66

11

1 1

20kHz-3MHz

22

2

PPrimary P rim rim ary ary

6 6

SSecondary S econdary econdary

Primary

Secondary

Primary

Secondary

44

4

80171

TRANSFORMERS & INDUCTORS

16

Transformer Parameters

6.5kW Max Power

SIZE 350

17

ER51 (size 350) TRANSFORMERS & INDUCTORS ER41 (Size (Size 225) 225) ER41

20442379-01 2044

ER51 (size (size 350) ER51 350)

Transformer Specification Example

2379-01 2379-01

Dimension Diagram

80

Voltage

Current

ER51

6.5kW

220G

4kV

1000V

200A

Topologies • Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Inductor Application 1x10

Transformer Technical Information

SIZE 350

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies 100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Total Output Power Topology PSU Output DC Voltage & Current Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximumm Bus Voltage Turns Ratio

Primary to Secondary Cooling Ambient Temperature Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

1.8kW Full Bridge 225Vdc @ 8Adc (max) 3.8mH 25% (provisional) 4.7A rms 7.7A rms 80kHz 390V

17:11 Heatsink + Air 70oC Max

80 80

51

Dielectric Isolation

51 51

Weight

25 25 25

Power

25

Core

51

80

4000Vrms 2500Vrms 2500Vrms EN60950

111

66

1 1

20kHz-3MHz

333

3

5

5 5

Prim rim ary PP rim ary Primary ary Primary

Primary

econdary Secondary55 SSecondary Secondary Secondary

Secondary 44

4

4

Transformer Parameters Weight

Dielectric Isolation

Voltage

Current

E64

10kW

400G

4kV

1000V

500A

• Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Inductor Application

Transformer Technical Information

SIZE 500

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary

100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

20kHz-3MHz

132202 105 105

Total Output Power Topology PSU Output DC Voltage & Current Maximum Duty Cycle Primary inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Cooling Ambient Temperature Insulation Working Voltage Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

7.6kW Full Bridge ZVS 58.2V / 130A 0.9 1.3mH 25% 22.5A rms 92A rms (each half) 100kHz 420V 622V 12:(2+2) Forced Cooling 2m/s -10oC to 40oC 600V rms 4000Vrms 2000Vrms 2000Vrms EN60950

65

Power

105

E64 (size 500)

64 65

Core

3

Dimension Diagram

Transformer Specification Example

Topologies

1x10

105

65

SIZE 500

132202 2044 2044 132202

30

10kW Max Power

19

E64 (size 500) ER41 (Size (Size 225) 225) ER41 E64 (size 500)

30 30

18

TRANSFORMERS & INDUCTORS

30

TRANSFORMERS & INDUCTORS

11 1

66

1 Prim rimary ary P Primary P 1rimary

Primary

33 3

3

Primary

6

6

Secondary econdary Secondary Secondary 55 S 6

Secondary 4

4 Secondary 4

4

TRANSFORMERS & INDUCTORS

20

Transformer Parameters

Transformer Specification Example

10kW

400G

4kV

Voltage

Current

1000V

300A

Topologies • Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Inductor Application 1x10

Transformer Technical Information

SIZE 510

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary

4kVrms

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

Total Output Power Topology PSU Output DC Voltage & Current Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Cooling Ambient Temperature Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

6kW Phase Shift Full Bridge 200V @ 30A dc 17.5μH 25% (provisional) 344A rms 29A rms 38kHz 18V 32V 1:12 Heatsink at 70oC

4000Vrms 2500Vrms 2500Vrms EN60950

65

ER64

87 87

65

Weight

11 1

1

20kHz-3MHz

1 100

10

100

1x10

Ampere Turns

3

1x10

4

3 33

6 6

rimary Primary PPP rim rimary ary

8016

8016

Dimension Diagram

64 65

Power

87

ER64 (Size 500)

30

Core

Dielectric Isolation

2044 2044

87

30 30

SIZE 510

ER41 (Size 225) ER41 (Size 225)

30

10kW Max Power

21

ER64 (Size 500) TRANSFORMERS & INDUCTORS

6

5 Secondary Secondary Secondary 5 Secondary

Primary

Secondary 4

Primary

Secondary

4

6 6

4

TRANSFORMERS & INDUCTORS

22

Transformer Parameters Current

E102

15kW

1KG

4kV

1000V

750A

• Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Transformer Technical Information Isolation Voltage:

Typical AL (nH/ t 2)

Primary - Secondary

100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

20kHz-1MHz

Total Output Power Topology PSU Output DC Voltage & Current Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Cooling Ambient Temperature Insulation Test Voltage

Primary to Secondary

Primary to Secondary

Secondary to Core Standard

12kW Full Bridge LLC 48V @ 250A max 5mH 25% 29A rms 230A rms 50kHz 380 420 23:3 Heatsink -40oC to +60oC 1000Vrms 1000Vrms 1000Vrms EN60950

102

Voltage

102

Dielectric Isolation

102 102

Weight

SIZE 540

175

44

Power

3

Dimension Diagram

175 175

Core

Topologies

1x10

175

Transformer Specification Example

Inductor Application

2044 2044

44 44

SIZE 540

ER41 (Size 225) ER41 (Size 225)

44

15kW Max Power

23

TRANSFORMERS & INDUCTORS

1 11

6 6

6

6

1 rimary PPP rim rimary ary 1 Primary

5 Secondary Secondary Secondary 5 Secondary 6

Primary

Secondary

3 3 3 Primary

4 Secondary

3

4

4

TRANSFORMERS & INDUCTORS

24

Transformer Parameters

E102

30kW

1.5KG

4kV

1000V

1000A

• Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Transformer Technical Information

SIZE 1080

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary

100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Total Output Power Topology PSU Output DC Voltage & Current Magnetizing Inductance Primary Winding Current Switching Frequency Bus Voltage Duty (pulsed power) Turns Ratio Primary to Secondary Cooling Insulation Test Voltage Primary to Secondary

Primary to Core

Secondary to Core Standard

18kW Full Bridge 300V @ 240dc Peak 5.1mH 10% 87A rms 50kHz 500-700V 0.33 16:8 Clamped to Cold Plate Est. 40 Degrees C 4000Vrms 2500Vrms 2500Vrms EN60950

102

Current

102

Voltage

102 102

Dielectric Isolation

Inductor Application

175

44

Weight

3

Dimension Diagram

175 175

Power

Topologies

1x10

175

Transformer Specification Example

Core Double

2044 2044

44 44

SIZE 1080

ER41 (Size 225) ER41 (Size 225)

44

30kW Max Power

25

TRANSFORMERS & INDUCTORS

11 1

6 6

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

1

Switching Frequencies

20kHz-1MHz

Prim rimary P ary 1 Primary P rimary

6 5 Secondary Secondary Secondary 6 5 Secondary

Primary

Secondary

3 3 3 Primary

4 Secondary

3

6

4

4 4

Weight

Dielectric Isolation

Voltage

Current

E153

50kW

3KG

4kV

1000V

1200A

• Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Inductor Application

Transformer Technical Information

SIZE 1200

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary

100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

20kHz-500kHz

Dimension Diagram

80156

220

E153 (Size 1200)

80156

220 220 220

Total Output Power Topology PSU Output DC Voltage Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Cooling Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

25kW Full Bridge 200-400V 12.3mH 25% 45.2A rms 62A rms 20kHz 584V 800V 36:18 Clamp + Heatsink + air flow

153

Power

80156

E153 (Size 1200)

153

Core

2044 2044

E153 (Size 1200)

Transformer Specification Example

Topologies

1x10

ER41 (Size (Size 225) 225) ER41

62

SIZE 1200

TRANSFORMERS & INDUCTORS

153 153

Transformer Parameters

50kW Max Power

27

62

26

62 62

TRANSFORMERS & INDUCTORS

4000Vrms 2500Vrms 2500Vrms EN60950

11 1 1 1

66

rim aryary ary PPrim ary Prim Primary

Primary 33 3 3 3

66 6

Secondary Secondary Secondary Secondary econdary 55 S Secondary 44

44 4

TRANSFORMERS & INDUCTORS

28

Transformer Parameters

80kW Max Power

SIZE 2400

29

TRANSFORMERS & INDUCTORS

Transformer Specification Example

E153Double Double(size (size2000) 2000) E153 E153 Double (size 2000)

Dimension Diagram

E153 Double (size 2000) E153 Double (size 2000)

280 280 280

80175 80175 80175 80175 80175

280

Current

E153

80kW

4KG

4kV

1000V

1200A

Double

Topologies • Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Inductor Application 1x10

Transformer Technical Information

SIZE 2400

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary Primary - Core Secondary - Core Switching Frequencies

100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms 2.5kVrms

Total Output Power Topology Primary Voltage Primary Inductance Primary Winding Current Secondary Winding Current Switching Frequency Turns Ratio

Primary to Secondary Cooling Ambient Temperature Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

45kW Full Bridge 600V 2.9mH 75A 75A 30kHz 10: (5+5 / 5+5) Natural Air Cooled 65oC Ambient 4000Vrms 4000Vrms 4000Vrms EN60950

280 280

153 153 153

Voltage

62 62

Dielectric Isolation

62

Weight

153 153153

Power

62 6262

Core

111

2.5kVrms

1 1

888 8

PrimaryPrimary

6Secondary SSecondary 66S econdary Secondary 6econdary 6Secondary

Prim ary Prim aryPrimary Primary

20kHz-500kHz

333

3 3

8

7 777 7

5

555 5 4 444 4

Power

E153

Weight

120kW

Triple

Transformer Specification Example Dielectric Isolation

Voltage

4kV

1000V

13KG

Current 1200A

• Full Bridge • Half Bridge • Boost • Resonant • Push Pull • Buck

Inductor Application 1x10

Transformer Technical Information

SIZE 3600

3

Isolation Voltage: Typical AL (nH/ t 2)

Primary - Secondary

100

10

100

1x10

Ampere Turns

3

1x10

4

4kVrms

Primary - Core

2.5kVrms

Secondary - Core

2.5kVrms

Switching Frequencies

20kHz-500kHz

Total Output Power Topology PSU Output DC Voltage & Current Primary Inductance Leakage Inductance Primary Winding Current Secondary Winding Current Switching Frequency Minimum Bus Voltage Maximum Bus Voltage Turns Ratio

Primary to Secondary Cooling Insulation Test Voltage

Primary to Secondary

Primary to Core

Secondary to Core Standard

100kW Full Bridge 500Vdc @ 200Adc (max) 800 - 900μH <1μH

2044 2044

Dimension Diagram

E153 Triple (Size 3600) E153 Triple (Size 3600) E153 Triple (Size 3600)

310

80049 80049 80049

310 310 310

153

Core

ER41 (Size (Size 225) 225) ER41

133A rms 200A rms 20kHz 750V 820V 62

SIZE 3600

TRANSFORMERS & INDUCTORS

153 153

Transformer Parameters

120kW Max Power

31

12:8 Heatshunts / Coldplate 4000Vrms 2500Vrms 2500Vrms EN60950

62 62 62

30

153

TRANSFORMERS & INDUCTORS

111 1 1

66

rim ary P rimary PPP rim ary Primary rim

Primary

33 3 3 3

6 6 6

Secondary Secondary Secondary Secondary econdary 55 S Secondary

44

4 4 4

CUSTOM DESIGN

150kW Planar Transformer Himag Planar specialises in high power planar transformers.

The great challenge is thermal performance of these high power parts. One option Himag employs to overcome this is by using multiple units hence increasing the thermal conduction area. This example is a single transformer assembly using two planar transformers that are connected in series & parallel to achieve 150kW.

Specification:

• Total output power - 150kW (2 x 75kW) • High Efficiency >99% • Leakage <0.01% • Frequency - 20kHz • Mechanical dimensions: Length - 349 mm, Width - 375mm, Height - 72.5 mm • Weight - 22.6kg

32

33

CUSTOM DESIGN

Medical Planar Transformer A Planar Transformer with a continuous power rating of 6.5kW with short periods that require 12kW. The transformer is designed with 2 pairs of E64 ferrite cores and is mounted on a baseplate with an aluminium heatsink clamp. The transformer has a turn’s ratio of 11:2+2:17.

This transformer is in the power supply for a medical CTI scanner and it is housed in the rotating part of the equipment that exerts pressures of 6G. The terminals for the primary winding and two separate secondary windings are made using Litz wires that are connected prior to potting of the part. The potting is not only important to the thermal capabilities of the transformer but also plays an important role in the structural integrity of the part.

Power Converter This is a fully integrated planar magnetic, high voltage DCDC Converter for a telecoms application. This is a resonant based design operating at a switching frequency of 20kHz. The converter runs from a low voltage DC Bus and is capable of delivering a high voltage output of up to 4kV @ 1A DC. The main power transformer and output inductors are embedded within a single multilayer PCB. All other discrete components are mounted as either SMT or PTH devices on the same multilayer layer PCB: • Rectification Diodes (SMT) • Filter Capacitors (PTH) • Feedback components (PTH) • Protection Devices (PTH)

High Voltage Isolation Transformer High voltage isolation can present a challenge to any insulation system. Himag Planar overcame this (in this case 20kV) by a hybrid approach with the primary windings using a HV Insulated wire and the secondary planar leadframes. This solution improves the transformer size and performance. The use of multiple cores allows for higher power ratings due to the increased effective area of the ferrite.

THERMAL HANDLING / COOLING

34

In operation Transformers and Inductors generate significant heat, and this heat has to be dealt with. It is much more efficient to cool these parts by conduction rather than convection (radiation). The low profile flat nature of the Planar Transformer provides a relatively large core surface area ideal for conduction cooling. The flat planar windings of the component can also utilise conduction cooling by the placing aluminium blocks between the windings and the same cooling surface of the core.

The following cooling methods are used by Himag in the majority of designs:The Water Cooled plate is a very efficient heatsink method as the temperature of the cooling surface can be maintained at a constant temperature by the use of a coolant.

Single Sided Cooling

TERMINATIONS

35 Just Some Of Our Terminations

Himag Planar offers a wide range of connection/termination options for its transformers. Some examples of existing designs are shown below. We are happy to provide any custom termination arrangement.

Multi-Pin PCB Mounting

Bolted Connections

Power Soldered Leads

Horizontal PCB Mounting

Customised Extended Lead-Frames

Fly Leads

Vertical PCB Mounting

Bolted and Soldered Connections

Vertical PCB to PCB

The magnetic component is mounted direct to a cold plate or heatsink providing a single cooling surface for both the core and windings.

Two Sided Cooling As well as being mounted on a heatsink or cold plate the top surface can also be cooled by a clamping bar providing a thermal path from the top surface of the component to the heatsink or cold plate via the mounting parts.

Three Sided Cooling Achieved by a formed clamp bracket providing a thermal path from the top and sides of the part down to the cold plate or heatsink.

Finned Heatsinks & Forced Air: provide a conduction and radiation method for single, double, and three sided cooling with the same construction methods as the water cooled plate. The fins of the heatsink increase the surface area of the cooling medium, and further improvement is achieved by applying forced air over the component, with the fins significantly improving the thermal radiation process.

The use of thermal grease, high thermal conductive tapes, and adhesives can be employed to further enhance the thermal performance of the component in all of the above cooling methods.

Potting the component with a high thermally conductive resin material can further improve thermal performance. The ingress of the potting material into the component assuring all surfaces of all materials have a thermal path to the cooling surface. The additional mass of the component as a result of the potting material will also improve the thermal process by absorption of the heat.

The following table provides typical Thermal Impedance for some of the cooling options for a size 500 Transformer Natural Cooling (Hot Spot – Air)

Blowing Air 3ms/sec (Hot Spot-Air)

One Side Heatsink (Hot Spot - Heatsink)

Two Side Heatsink (Hot Spot-Heatsink)

1.7 ºC/W

1.3 ºC/W

1.6 ºC/W

0.8 ºC/W

CONVENTIONAL PARTS

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OTHER PRODUCTS

A World Of Transformers Under One Roof On top of Planar Transformers, Himag also offer a wide range of Wire Wound Transformers, Choke Coils & Line Filters.

Power Supply & Adaptors

OEM & Turnkey Projects

CONTACT US

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Tel: +44 (0) 1452 722 351 Fax: +44 (0) 1452 881 360 Email: sales@himag.co.uk www.himag.co.uk

Himag Planar Magnetics Ltd Unit A The Aquarius Centre, Edison Close, Waterwells Business Park, Quedgeley, Gloucestershire, GL2 2FN United Kingdom

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www.himag.co.uk