New Zero Voltage Transition Full Bridge Planar Transformer

 The preferred topology for switched power supplies over 500W is Full Bridge. The large offer of efficient low RDSon Mosfet transistors made designers chose this topology as it is more efficient and reliability as the support lower DS Voltage when open. This technology allows a smaller transformer as it works in 4 quadrants then optimizing the magnetic circuit. Smaller transformers with high isolation and above all low losses thanks to the use of the best soft magnetic materials as well as innovative winding, isolating and thermal coupling techniques made this new 2400 Watts Planar transformer a light and efficient solution for high power density Power Electronics devices. The heatsink is designed to operate below 75 ºC and to be assembled with 4 M4 screws on a water plate.

With isolation of min 2000 Veff and a turn ratio of 18:1 it has been designed for Electric Vehicles with Vin 350-420VDC and Vout 14V and 180A. Switching frequency for optimum operation is 70Khz. The complete transformer is Class H 180ºC according to IEC85 and UL94V0. The connections are specially for high current and quick tinless assembly with the output inductor.

The design is specially made for connection of the main transformer and output choke together with screw. The main characteristics are:

Transformer:

• Input voltage: 340-450 (High voltage battery automotive systems)
• Output voltage: 14Vdc after rectification (to supply electronics inside the car)
• Output current: 130 Adc continuously and 180 Adc peak (10 minutes max)
• Total output power: 1800 Watt continuously
• Max losses: 10 Watt
• Dimensions: 70X80X31.5mm

Output choke:

• Inductance value: 1.6uH
• Peak current: 150 Amp
• Inductance value at peak current: 1.6uH (no saturation)
• Ripple current: 34 App @ 140kHz
• Max losses: 6 Watt
• Dimensions:55X65X30mm

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Premo Group is a worldwide leading company designing, manufacturing and supplying standard or custom made inductive components for the electronics market. Our wide range of products as RFID transponder coils, EMC filters, PLC accessories, planar transformers, current transducers and chokes cover most applications in the different market sectors.