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