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8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 15
11142012 1 of 3
983209 Copyright 2012 Pulse Electronics Inc Subject to change without notice All rights reserved
Flat Coil Planar Transformers
by Gerard Healy Pulse (httppulseelectronicscom)
Introduction
Pulse has led the development of planar magnetics providing technical solutions for datacom
industrial automation amp control aeronautics and robotics industry over the last 20 years Much has been written
about the benefits of planar over conventional wound magnetics The reader is referred to
983144983156983156983152983098983087983087983159983159983159983086983152983157983148983155983141983141983148983141983139983156983154983151983150983145983139983155983086983139983151983149983087983140983151983159983150983148983151983137983140983087983091983095983097983090983087983143983088983092983093 for more information
As a discrete component the planar transformer have been primarily implemented as a high power
(gt100W) low profile (lt 10mm) solution for medium to low voltage conversions because of the current handing
capabilities of the planar windings A typical example is the intermediate bus converter in the distributed power
architecture Emerging trends have increased the popularity of this product as an embedded cost saving
technique despite the price premium associated with a planar solution This paper discusses the distributed
power architecture the recent trends that are driving new opportunities for planar magnetics and cost effectiveplanar solutions A new generation pulse product offering is presented that both increases the technical
performance compared to the existing offering and reduces the price Finally further development activity is
outlined which is further reducing the price increasing the power capability and functionality of new pulse
planar solutions
The Distributed Power Architecture amp emerging magnetic requirements
Since it first began to replace the central power source in the 1980rsquos the Distributed Power
Architecture (DPA) has been implemented in a wide variety of complex electronic systems By eliminating the
need of a direct wiring between the source and each individual loads replacing this with bus voltages and Point
of Load (POL) conversions the DPA is smaller in size and higher in efficiency The fundamental blocks of the
DPS are shown in the following diagram
Distributed Power Architecture
The front end ACDC converter provides reinforced insulation from the mains source and a medium
level bus voltage The isolated Intermediate Bus Converter (IBC) provided a loosely regulated lower board
level voltage The POL regulator provides the very low voltage conversion as close as possible to the load This
minimises the length of high current tracks and improves the system efficiency The DPA is adaptable and
scalable according to the emerging power needs of the system
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 25
11142012 2 of 3
983209 Copyright 2012 Pulse Electronics Inc Subject to change without notice All rights reserved
While the front end ACDC converter has largely remained a centralised power source at a system
level the popularity of the DPA has driven the DCDC converter market into a multibillion dollar industry A
wide range of power modules are available with standardised input and output voltages and tailored for various
market requirements Pulse has developed a wide portfolio of magnetics for DCDC conversion from low cost
inductors for the POL to high end transformers for the IBC with constructions ranging for low cost convention
wound for lower power to planar windings for applications that require higher currents in a low profile
In the recent years a second quiet revolution has taken place that has driven the development of a new
range of magnetics The DPA needed to adjust to the requirements of more complex and power hungry loads
DSPrsquos FPGArsquos and ASICrsquos requiring careful load monitoring and power sequencing has lead to a wider
implementation of POLrsquos with digital controllers to facilitate the load management Increasing current levels
has driven the requirement for higher efficiency inductors While this topic is not covered by this paper the
reader is referred to 983144983156983156983152983098983087983087983159983159983159983086983152983157983148983155983141983141983148983141983139983156983154983151983150983145983139983155983086983139983151983149983087983140983151983159983150983148983151983137983140983087983091983095983096983097983087983143983088983092983092 for more information
A direct consequence of the wider implementation of POLrsquos is a simplification of the IBC Previously
these tended to be complex multiple output modules to provide several voltage rails These are now being
replaced with single output converters and with the strong trend to implement these as an embedded solution
However the increasing power requirements and the height restrictions demand low profile high efficiency andcost effective solutions Conventional wound magnetics may still satisfy the power requirements up to 100W
Above 100W these solutions become quite bulky
The planar transformer with its low profile windings is the optimum technical solution However
these currently come with a significant price premium The focus of this paper will be on an alternative winding
technology for cost optimisation
Flat Coil winding technology
Planar magnetics achieve higher power in lower profile by replacing the cores and windings of
conventional wound magnetics with flatter alternatives Traditionally Pulse has used planar cores with multi
layer PCB for the medium voltagemedium current primary winding and copper plates for the low voltage high
current secondary winding of the IBC transformer Two standard series planars are available the PA08xxNL amp
PA09xNL (Gen1) series with power capabilities up to 140W and 250W respectively
The PCB is the most significant cost factor its cost linked directly to its size and manufacturing
volume There is limited design flexibility and a new tooling required for each variation While some economies
of scale have been achieved on the 140W series the cost increases rapid for higher currents (more PCB layers)
and larger platforms (more PCB area)
Pulse has developed a cost effective alternative by replacing the multilayer PCB winding with a flat
coil windings reducing the price by approximately 20 The copper fill factor of this technology is twice that
of PCB so the DCR of the primary winding is reduce by 50 in the new generation (Gen2) PH08xxNL andPH09xxNL series This increases the power rating by 20 in the a new size and pin compatible standard series
Eliminating the cost and time to fabricate PCBrsquos for new winding arrangements the flat coil planar has the
additional advantages of flexibility and speed to prototype custom variations
Further technological advantages of Flat Coil windings
For power levels up to ~ 150W the forward converter topology is commonly selected and the
PA08xxNL had been an effective transformer solution However for the next power range other topologies
such as Push Pull and Half Bridge are generally chosen These require centre taped windings and with current
conduction in the windings only during certain periods of the switching cycles the coupling between windings
becomes a critical design aspect Traditional multilayer PCB windings with up to 8 consecutive winding layers
give rise to high leakage inductance producing unacceptably high voltage spikes and snubber circuit losses
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 35
11142012 3 of 3
983209 Copyright 2012 Pulse Electronics Inc Subject to change without notice All rights reserved
The multilayer PCB can be replaced with lower number of flat coil winding layers connected in series
This provides immediate benefits by reducing AC proximity effect copper losses In addition more winding
segments and selective coupling between simultaneously conduction windings can be implemented to reduce the
leakage inductance This improved interleaving capability has been demonstrated to improved transformer
efficiencies for higher power customised designs on standard platforms The following is a case study for a
444 ratio bridge topology transformer and the reduction in leakage for when using flat coil windings whichyielded a increase in PSU efficiency from 952 to 975
983107983151983150983158983141983150983156983145983151983150983137983148 983120983148983137983150983137983154 983107983151983150983155983156983154983157983139983156983145983151983150 983119983152983156983145983149983145983155983141983140 983107983151983150983155983156983154983157983139983156983145983151983150
983124983157983154983150983155 983122983137983156983145983151
983118983152983098983118983155983098983118983155983092983098983092983098983092 983092983098983092983098983092
983123983156983137983139983147 983157983152983089983124983087983123983141983139 983105983087983089983124983087983089983124983087983123983141983139 983106983087983089983124
983110983151983157983154 983089983124 983139983151983150983150983141983139983156 983145983150 983155983141983154983145983141983155
983123983141983139 983105 983090983124983087983120983154983145 983090983124983087983123983141983139 983106 983090983124983087983123983141983139 983105 983090983124983087983120983154983145 983090983124983087983123983141983139 983106 983090983124
983090983124 983120983154983145983149983137983154983161983084 983123983141983139 983105 983078 983123983141983139 983106 983139983151983150983150983141983139983156 983145983150 983155983141983154983145983141983155
983116983141983137983147983137983143983141 983113983150983140983157983139983156983137983150983139983141
983080983150983112983081983089983091983088 983097983095
The Next Generation (Gen3) Planar Transformer
The manual pining and soldering of the current planar construction is a second significant cost factor
To address this Pulse is developing a new process that greatly reduces the assembly time A pinned header
allows the individual winding elements to be quickly stacked and terminated by solder immersion
A modification to the pad layout for the flat pins of the pinned header is required if replacing a round
pin Gen1 or Gen2 planar However with a 20 further price reduction compare to the Gen2 version the Gen3
solution is recommended for new designs PH08xxCNL and PH09xxCNL series are being developed as
alternatives to the current product offering with a new and larger PH10xxCNL platform extending the powercapability to 500W
Conclusion
Pulse continues to address the market needs with ongoing development of planar platforms and
winding technologies The new Gen2 series is drop in replacement standard product offering for immediate
price reduction Gen3 products offer further price reduction for new development activity The current
development road map includes optimised core designs to push the power capability up to 1KW as well as an
innovative winding technology to minimise leakage inductance for higher power transformer design and higher
levels of isolations The reader is encouraged to contact Pulse to discuss their particular needs The annex to this
paper provides an overview of the complete planar product offering
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 45
Product Overview Planar Transformer (1112)1 pulseelectronicscom
Gen 2 Planar Flat Coil Winding
20 price reduction compared to PCB
50 lower DCR
Power Rating up to 300W
Platforms 2 sizes 23x22mm to 29x27mm
Height lt 119mm profileSMD 1500Vdc Isolation
Custom design capability up to 1KW4KV
Low profilehigh efficiency bus converters
for distributed power architecture
Datacom System CardsIndustrial Control
Robotics
New Generation Product Offering
Applications
Power gt 100W Flat Coil Planar
Busconverter
Busconverter
AC-DCconverter System
card
Systemcard
Systemcard
Isolationbarrier
Busconverter
POL regulator
POL regulator
POL regulator
POL regulator
POL regulator
IO
FPGA
Core Vcore
Distributed bus
Intermediate bus8V to 14V
Distributed Power Architecture
Product Overview Planar Transformer
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 55
Product Overview Planar Transformer (1112)2 pulseelectronicscom
For More Information
Pulse WorldwideHeadquarters12220 World Trade DriveSan Diego CA 92128USA
Tel 858 674 8100Fax 858 674 8262
Pulse EuropeZeppelinstrasse 1571083 HerrenbergGermany
Tel 49 7032 7806 0Fax 49 7032 7806 12
Pulse China HeadquartersB402 Shenzhen Academy ofAerospace Technology Bldg10th Kejinan RoadHigh-Tech ZoneNanshan DistrictShenzen PR China 518057Tel 86 755 33966678Fax 86 755 33966700
Pulse North ChinaRoom 27042705Super Ocean Finance Ctr2067 Yan An Road WestShanghai 200336China
Tel 86 21 62787060Fax 86 2162786973
Pulse South Asia135 Joo Seng Road03-02PM Industrial BldgSingapore 368363
Tel 65 6287 8998Fax 65 6287 8998
Pulse North Asia3F No 198 ZhongyuanRoadZhongli CityTaoyuan County (32068)Taiwan
Tel 886 3 4356768Fax 886 3 4356823
Performance warranty of products offered on this data sheet is limited to the parameters specified Data is subject to change without notice Other brand and product names mentioned herein may be trademarks or
registered trademarks of their respective owners copy Copyright 2012 Pulse Electronics Inc All rights reserved
wwwPulseElectronicscomdownload3794G046
Series Platform Power RatingFootprint
(mm)
Height
(mm)
Primary Numbers
Turns
Primary DCR
(mOhms)
Secondary Number
Turns
Secondary DCR
(mOhms)PA08xxNL ER19 Gen 1 up to 140W 234 x 216 lt97 4 - 12 9 - 50 1 - 4 045 - 7
PH08xxNL ER19 Gen 2 Up to 160W 234 x 216 lt91 4 - 12 4 - 28 1 - 4 045 - 7
PH08xxCNL ER19 Gen 3 Up to 160W 247 x 216 lt96 3 - 12 35 - 28 1 - 4 05 - 7
PA09xxNL ER25 Gen 1 up to 250W 295 x 254 lt104 4 - 16 6 - 120 1 - 4 028 - 80
PH09xxNL ER25 Gen 2 Up to 300W 295 x 267 lt119 4 - 16 34 - 27 1 - 4 028 - 45
PH09xxCNL ER25 Gen 3 Up to 300W 305 x 270 lt126 2 - 16 18 - 27 1 - 4 038 - 46
PH10xxCNL ER28 Gen 3 Up to 500W 355 x 305 lt126 2 - 16 1 - 14 1 - 4 039 - 40
Gen 1 Gen 2 Gen 3Legacy PCB product line Flat Coil pin compatable with Gen 1 Pinned header amp flat coil
20 Further price reduction
Modified pad layout
Custom developmentbottom view
Product Overview Planar Transformer
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 25
11142012 2 of 3
983209 Copyright 2012 Pulse Electronics Inc Subject to change without notice All rights reserved
While the front end ACDC converter has largely remained a centralised power source at a system
level the popularity of the DPA has driven the DCDC converter market into a multibillion dollar industry A
wide range of power modules are available with standardised input and output voltages and tailored for various
market requirements Pulse has developed a wide portfolio of magnetics for DCDC conversion from low cost
inductors for the POL to high end transformers for the IBC with constructions ranging for low cost convention
wound for lower power to planar windings for applications that require higher currents in a low profile
In the recent years a second quiet revolution has taken place that has driven the development of a new
range of magnetics The DPA needed to adjust to the requirements of more complex and power hungry loads
DSPrsquos FPGArsquos and ASICrsquos requiring careful load monitoring and power sequencing has lead to a wider
implementation of POLrsquos with digital controllers to facilitate the load management Increasing current levels
has driven the requirement for higher efficiency inductors While this topic is not covered by this paper the
reader is referred to 983144983156983156983152983098983087983087983159983159983159983086983152983157983148983155983141983141983148983141983139983156983154983151983150983145983139983155983086983139983151983149983087983140983151983159983150983148983151983137983140983087983091983095983096983097983087983143983088983092983092 for more information
A direct consequence of the wider implementation of POLrsquos is a simplification of the IBC Previously
these tended to be complex multiple output modules to provide several voltage rails These are now being
replaced with single output converters and with the strong trend to implement these as an embedded solution
However the increasing power requirements and the height restrictions demand low profile high efficiency andcost effective solutions Conventional wound magnetics may still satisfy the power requirements up to 100W
Above 100W these solutions become quite bulky
The planar transformer with its low profile windings is the optimum technical solution However
these currently come with a significant price premium The focus of this paper will be on an alternative winding
technology for cost optimisation
Flat Coil winding technology
Planar magnetics achieve higher power in lower profile by replacing the cores and windings of
conventional wound magnetics with flatter alternatives Traditionally Pulse has used planar cores with multi
layer PCB for the medium voltagemedium current primary winding and copper plates for the low voltage high
current secondary winding of the IBC transformer Two standard series planars are available the PA08xxNL amp
PA09xNL (Gen1) series with power capabilities up to 140W and 250W respectively
The PCB is the most significant cost factor its cost linked directly to its size and manufacturing
volume There is limited design flexibility and a new tooling required for each variation While some economies
of scale have been achieved on the 140W series the cost increases rapid for higher currents (more PCB layers)
and larger platforms (more PCB area)
Pulse has developed a cost effective alternative by replacing the multilayer PCB winding with a flat
coil windings reducing the price by approximately 20 The copper fill factor of this technology is twice that
of PCB so the DCR of the primary winding is reduce by 50 in the new generation (Gen2) PH08xxNL andPH09xxNL series This increases the power rating by 20 in the a new size and pin compatible standard series
Eliminating the cost and time to fabricate PCBrsquos for new winding arrangements the flat coil planar has the
additional advantages of flexibility and speed to prototype custom variations
Further technological advantages of Flat Coil windings
For power levels up to ~ 150W the forward converter topology is commonly selected and the
PA08xxNL had been an effective transformer solution However for the next power range other topologies
such as Push Pull and Half Bridge are generally chosen These require centre taped windings and with current
conduction in the windings only during certain periods of the switching cycles the coupling between windings
becomes a critical design aspect Traditional multilayer PCB windings with up to 8 consecutive winding layers
give rise to high leakage inductance producing unacceptably high voltage spikes and snubber circuit losses
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 35
11142012 3 of 3
983209 Copyright 2012 Pulse Electronics Inc Subject to change without notice All rights reserved
The multilayer PCB can be replaced with lower number of flat coil winding layers connected in series
This provides immediate benefits by reducing AC proximity effect copper losses In addition more winding
segments and selective coupling between simultaneously conduction windings can be implemented to reduce the
leakage inductance This improved interleaving capability has been demonstrated to improved transformer
efficiencies for higher power customised designs on standard platforms The following is a case study for a
444 ratio bridge topology transformer and the reduction in leakage for when using flat coil windings whichyielded a increase in PSU efficiency from 952 to 975
983107983151983150983158983141983150983156983145983151983150983137983148 983120983148983137983150983137983154 983107983151983150983155983156983154983157983139983156983145983151983150 983119983152983156983145983149983145983155983141983140 983107983151983150983155983156983154983157983139983156983145983151983150
983124983157983154983150983155 983122983137983156983145983151
983118983152983098983118983155983098983118983155983092983098983092983098983092 983092983098983092983098983092
983123983156983137983139983147 983157983152983089983124983087983123983141983139 983105983087983089983124983087983089983124983087983123983141983139 983106983087983089983124
983110983151983157983154 983089983124 983139983151983150983150983141983139983156 983145983150 983155983141983154983145983141983155
983123983141983139 983105 983090983124983087983120983154983145 983090983124983087983123983141983139 983106 983090983124983087983123983141983139 983105 983090983124983087983120983154983145 983090983124983087983123983141983139 983106 983090983124
983090983124 983120983154983145983149983137983154983161983084 983123983141983139 983105 983078 983123983141983139 983106 983139983151983150983150983141983139983156 983145983150 983155983141983154983145983141983155
983116983141983137983147983137983143983141 983113983150983140983157983139983156983137983150983139983141
983080983150983112983081983089983091983088 983097983095
The Next Generation (Gen3) Planar Transformer
The manual pining and soldering of the current planar construction is a second significant cost factor
To address this Pulse is developing a new process that greatly reduces the assembly time A pinned header
allows the individual winding elements to be quickly stacked and terminated by solder immersion
A modification to the pad layout for the flat pins of the pinned header is required if replacing a round
pin Gen1 or Gen2 planar However with a 20 further price reduction compare to the Gen2 version the Gen3
solution is recommended for new designs PH08xxCNL and PH09xxCNL series are being developed as
alternatives to the current product offering with a new and larger PH10xxCNL platform extending the powercapability to 500W
Conclusion
Pulse continues to address the market needs with ongoing development of planar platforms and
winding technologies The new Gen2 series is drop in replacement standard product offering for immediate
price reduction Gen3 products offer further price reduction for new development activity The current
development road map includes optimised core designs to push the power capability up to 1KW as well as an
innovative winding technology to minimise leakage inductance for higher power transformer design and higher
levels of isolations The reader is encouraged to contact Pulse to discuss their particular needs The annex to this
paper provides an overview of the complete planar product offering
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 45
Product Overview Planar Transformer (1112)1 pulseelectronicscom
Gen 2 Planar Flat Coil Winding
20 price reduction compared to PCB
50 lower DCR
Power Rating up to 300W
Platforms 2 sizes 23x22mm to 29x27mm
Height lt 119mm profileSMD 1500Vdc Isolation
Custom design capability up to 1KW4KV
Low profilehigh efficiency bus converters
for distributed power architecture
Datacom System CardsIndustrial Control
Robotics
New Generation Product Offering
Applications
Power gt 100W Flat Coil Planar
Busconverter
Busconverter
AC-DCconverter System
card
Systemcard
Systemcard
Isolationbarrier
Busconverter
POL regulator
POL regulator
POL regulator
POL regulator
POL regulator
IO
FPGA
Core Vcore
Distributed bus
Intermediate bus8V to 14V
Distributed Power Architecture
Product Overview Planar Transformer
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 55
Product Overview Planar Transformer (1112)2 pulseelectronicscom
For More Information
Pulse WorldwideHeadquarters12220 World Trade DriveSan Diego CA 92128USA
Tel 858 674 8100Fax 858 674 8262
Pulse EuropeZeppelinstrasse 1571083 HerrenbergGermany
Tel 49 7032 7806 0Fax 49 7032 7806 12
Pulse China HeadquartersB402 Shenzhen Academy ofAerospace Technology Bldg10th Kejinan RoadHigh-Tech ZoneNanshan DistrictShenzen PR China 518057Tel 86 755 33966678Fax 86 755 33966700
Pulse North ChinaRoom 27042705Super Ocean Finance Ctr2067 Yan An Road WestShanghai 200336China
Tel 86 21 62787060Fax 86 2162786973
Pulse South Asia135 Joo Seng Road03-02PM Industrial BldgSingapore 368363
Tel 65 6287 8998Fax 65 6287 8998
Pulse North Asia3F No 198 ZhongyuanRoadZhongli CityTaoyuan County (32068)Taiwan
Tel 886 3 4356768Fax 886 3 4356823
Performance warranty of products offered on this data sheet is limited to the parameters specified Data is subject to change without notice Other brand and product names mentioned herein may be trademarks or
registered trademarks of their respective owners copy Copyright 2012 Pulse Electronics Inc All rights reserved
wwwPulseElectronicscomdownload3794G046
Series Platform Power RatingFootprint
(mm)
Height
(mm)
Primary Numbers
Turns
Primary DCR
(mOhms)
Secondary Number
Turns
Secondary DCR
(mOhms)PA08xxNL ER19 Gen 1 up to 140W 234 x 216 lt97 4 - 12 9 - 50 1 - 4 045 - 7
PH08xxNL ER19 Gen 2 Up to 160W 234 x 216 lt91 4 - 12 4 - 28 1 - 4 045 - 7
PH08xxCNL ER19 Gen 3 Up to 160W 247 x 216 lt96 3 - 12 35 - 28 1 - 4 05 - 7
PA09xxNL ER25 Gen 1 up to 250W 295 x 254 lt104 4 - 16 6 - 120 1 - 4 028 - 80
PH09xxNL ER25 Gen 2 Up to 300W 295 x 267 lt119 4 - 16 34 - 27 1 - 4 028 - 45
PH09xxCNL ER25 Gen 3 Up to 300W 305 x 270 lt126 2 - 16 18 - 27 1 - 4 038 - 46
PH10xxCNL ER28 Gen 3 Up to 500W 355 x 305 lt126 2 - 16 1 - 14 1 - 4 039 - 40
Gen 1 Gen 2 Gen 3Legacy PCB product line Flat Coil pin compatable with Gen 1 Pinned header amp flat coil
20 Further price reduction
Modified pad layout
Custom developmentbottom view
Product Overview Planar Transformer
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 35
11142012 3 of 3
983209 Copyright 2012 Pulse Electronics Inc Subject to change without notice All rights reserved
The multilayer PCB can be replaced with lower number of flat coil winding layers connected in series
This provides immediate benefits by reducing AC proximity effect copper losses In addition more winding
segments and selective coupling between simultaneously conduction windings can be implemented to reduce the
leakage inductance This improved interleaving capability has been demonstrated to improved transformer
efficiencies for higher power customised designs on standard platforms The following is a case study for a
444 ratio bridge topology transformer and the reduction in leakage for when using flat coil windings whichyielded a increase in PSU efficiency from 952 to 975
983107983151983150983158983141983150983156983145983151983150983137983148 983120983148983137983150983137983154 983107983151983150983155983156983154983157983139983156983145983151983150 983119983152983156983145983149983145983155983141983140 983107983151983150983155983156983154983157983139983156983145983151983150
983124983157983154983150983155 983122983137983156983145983151
983118983152983098983118983155983098983118983155983092983098983092983098983092 983092983098983092983098983092
983123983156983137983139983147 983157983152983089983124983087983123983141983139 983105983087983089983124983087983089983124983087983123983141983139 983106983087983089983124
983110983151983157983154 983089983124 983139983151983150983150983141983139983156 983145983150 983155983141983154983145983141983155
983123983141983139 983105 983090983124983087983120983154983145 983090983124983087983123983141983139 983106 983090983124983087983123983141983139 983105 983090983124983087983120983154983145 983090983124983087983123983141983139 983106 983090983124
983090983124 983120983154983145983149983137983154983161983084 983123983141983139 983105 983078 983123983141983139 983106 983139983151983150983150983141983139983156 983145983150 983155983141983154983145983141983155
983116983141983137983147983137983143983141 983113983150983140983157983139983156983137983150983139983141
983080983150983112983081983089983091983088 983097983095
The Next Generation (Gen3) Planar Transformer
The manual pining and soldering of the current planar construction is a second significant cost factor
To address this Pulse is developing a new process that greatly reduces the assembly time A pinned header
allows the individual winding elements to be quickly stacked and terminated by solder immersion
A modification to the pad layout for the flat pins of the pinned header is required if replacing a round
pin Gen1 or Gen2 planar However with a 20 further price reduction compare to the Gen2 version the Gen3
solution is recommended for new designs PH08xxCNL and PH09xxCNL series are being developed as
alternatives to the current product offering with a new and larger PH10xxCNL platform extending the powercapability to 500W
Conclusion
Pulse continues to address the market needs with ongoing development of planar platforms and
winding technologies The new Gen2 series is drop in replacement standard product offering for immediate
price reduction Gen3 products offer further price reduction for new development activity The current
development road map includes optimised core designs to push the power capability up to 1KW as well as an
innovative winding technology to minimise leakage inductance for higher power transformer design and higher
levels of isolations The reader is encouraged to contact Pulse to discuss their particular needs The annex to this
paper provides an overview of the complete planar product offering
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 45
Product Overview Planar Transformer (1112)1 pulseelectronicscom
Gen 2 Planar Flat Coil Winding
20 price reduction compared to PCB
50 lower DCR
Power Rating up to 300W
Platforms 2 sizes 23x22mm to 29x27mm
Height lt 119mm profileSMD 1500Vdc Isolation
Custom design capability up to 1KW4KV
Low profilehigh efficiency bus converters
for distributed power architecture
Datacom System CardsIndustrial Control
Robotics
New Generation Product Offering
Applications
Power gt 100W Flat Coil Planar
Busconverter
Busconverter
AC-DCconverter System
card
Systemcard
Systemcard
Isolationbarrier
Busconverter
POL regulator
POL regulator
POL regulator
POL regulator
POL regulator
IO
FPGA
Core Vcore
Distributed bus
Intermediate bus8V to 14V
Distributed Power Architecture
Product Overview Planar Transformer
8132019 Unit 4applications osc
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Product Overview Planar Transformer (1112)2 pulseelectronicscom
For More Information
Pulse WorldwideHeadquarters12220 World Trade DriveSan Diego CA 92128USA
Tel 858 674 8100Fax 858 674 8262
Pulse EuropeZeppelinstrasse 1571083 HerrenbergGermany
Tel 49 7032 7806 0Fax 49 7032 7806 12
Pulse China HeadquartersB402 Shenzhen Academy ofAerospace Technology Bldg10th Kejinan RoadHigh-Tech ZoneNanshan DistrictShenzen PR China 518057Tel 86 755 33966678Fax 86 755 33966700
Pulse North ChinaRoom 27042705Super Ocean Finance Ctr2067 Yan An Road WestShanghai 200336China
Tel 86 21 62787060Fax 86 2162786973
Pulse South Asia135 Joo Seng Road03-02PM Industrial BldgSingapore 368363
Tel 65 6287 8998Fax 65 6287 8998
Pulse North Asia3F No 198 ZhongyuanRoadZhongli CityTaoyuan County (32068)Taiwan
Tel 886 3 4356768Fax 886 3 4356823
Performance warranty of products offered on this data sheet is limited to the parameters specified Data is subject to change without notice Other brand and product names mentioned herein may be trademarks or
registered trademarks of their respective owners copy Copyright 2012 Pulse Electronics Inc All rights reserved
wwwPulseElectronicscomdownload3794G046
Series Platform Power RatingFootprint
(mm)
Height
(mm)
Primary Numbers
Turns
Primary DCR
(mOhms)
Secondary Number
Turns
Secondary DCR
(mOhms)PA08xxNL ER19 Gen 1 up to 140W 234 x 216 lt97 4 - 12 9 - 50 1 - 4 045 - 7
PH08xxNL ER19 Gen 2 Up to 160W 234 x 216 lt91 4 - 12 4 - 28 1 - 4 045 - 7
PH08xxCNL ER19 Gen 3 Up to 160W 247 x 216 lt96 3 - 12 35 - 28 1 - 4 05 - 7
PA09xxNL ER25 Gen 1 up to 250W 295 x 254 lt104 4 - 16 6 - 120 1 - 4 028 - 80
PH09xxNL ER25 Gen 2 Up to 300W 295 x 267 lt119 4 - 16 34 - 27 1 - 4 028 - 45
PH09xxCNL ER25 Gen 3 Up to 300W 305 x 270 lt126 2 - 16 18 - 27 1 - 4 038 - 46
PH10xxCNL ER28 Gen 3 Up to 500W 355 x 305 lt126 2 - 16 1 - 14 1 - 4 039 - 40
Gen 1 Gen 2 Gen 3Legacy PCB product line Flat Coil pin compatable with Gen 1 Pinned header amp flat coil
20 Further price reduction
Modified pad layout
Custom developmentbottom view
Product Overview Planar Transformer
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 45
Product Overview Planar Transformer (1112)1 pulseelectronicscom
Gen 2 Planar Flat Coil Winding
20 price reduction compared to PCB
50 lower DCR
Power Rating up to 300W
Platforms 2 sizes 23x22mm to 29x27mm
Height lt 119mm profileSMD 1500Vdc Isolation
Custom design capability up to 1KW4KV
Low profilehigh efficiency bus converters
for distributed power architecture
Datacom System CardsIndustrial Control
Robotics
New Generation Product Offering
Applications
Power gt 100W Flat Coil Planar
Busconverter
Busconverter
AC-DCconverter System
card
Systemcard
Systemcard
Isolationbarrier
Busconverter
POL regulator
POL regulator
POL regulator
POL regulator
POL regulator
IO
FPGA
Core Vcore
Distributed bus
Intermediate bus8V to 14V
Distributed Power Architecture
Product Overview Planar Transformer
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 55
Product Overview Planar Transformer (1112)2 pulseelectronicscom
For More Information
Pulse WorldwideHeadquarters12220 World Trade DriveSan Diego CA 92128USA
Tel 858 674 8100Fax 858 674 8262
Pulse EuropeZeppelinstrasse 1571083 HerrenbergGermany
Tel 49 7032 7806 0Fax 49 7032 7806 12
Pulse China HeadquartersB402 Shenzhen Academy ofAerospace Technology Bldg10th Kejinan RoadHigh-Tech ZoneNanshan DistrictShenzen PR China 518057Tel 86 755 33966678Fax 86 755 33966700
Pulse North ChinaRoom 27042705Super Ocean Finance Ctr2067 Yan An Road WestShanghai 200336China
Tel 86 21 62787060Fax 86 2162786973
Pulse South Asia135 Joo Seng Road03-02PM Industrial BldgSingapore 368363
Tel 65 6287 8998Fax 65 6287 8998
Pulse North Asia3F No 198 ZhongyuanRoadZhongli CityTaoyuan County (32068)Taiwan
Tel 886 3 4356768Fax 886 3 4356823
Performance warranty of products offered on this data sheet is limited to the parameters specified Data is subject to change without notice Other brand and product names mentioned herein may be trademarks or
registered trademarks of their respective owners copy Copyright 2012 Pulse Electronics Inc All rights reserved
wwwPulseElectronicscomdownload3794G046
Series Platform Power RatingFootprint
(mm)
Height
(mm)
Primary Numbers
Turns
Primary DCR
(mOhms)
Secondary Number
Turns
Secondary DCR
(mOhms)PA08xxNL ER19 Gen 1 up to 140W 234 x 216 lt97 4 - 12 9 - 50 1 - 4 045 - 7
PH08xxNL ER19 Gen 2 Up to 160W 234 x 216 lt91 4 - 12 4 - 28 1 - 4 045 - 7
PH08xxCNL ER19 Gen 3 Up to 160W 247 x 216 lt96 3 - 12 35 - 28 1 - 4 05 - 7
PA09xxNL ER25 Gen 1 up to 250W 295 x 254 lt104 4 - 16 6 - 120 1 - 4 028 - 80
PH09xxNL ER25 Gen 2 Up to 300W 295 x 267 lt119 4 - 16 34 - 27 1 - 4 028 - 45
PH09xxCNL ER25 Gen 3 Up to 300W 305 x 270 lt126 2 - 16 18 - 27 1 - 4 038 - 46
PH10xxCNL ER28 Gen 3 Up to 500W 355 x 305 lt126 2 - 16 1 - 14 1 - 4 039 - 40
Gen 1 Gen 2 Gen 3Legacy PCB product line Flat Coil pin compatable with Gen 1 Pinned header amp flat coil
20 Further price reduction
Modified pad layout
Custom developmentbottom view
Product Overview Planar Transformer
8132019 Unit 4applications osc
httpslidepdfcomreaderfullunit-4applications-osc 55
Product Overview Planar Transformer (1112)2 pulseelectronicscom
For More Information
Pulse WorldwideHeadquarters12220 World Trade DriveSan Diego CA 92128USA
Tel 858 674 8100Fax 858 674 8262
Pulse EuropeZeppelinstrasse 1571083 HerrenbergGermany
Tel 49 7032 7806 0Fax 49 7032 7806 12
Pulse China HeadquartersB402 Shenzhen Academy ofAerospace Technology Bldg10th Kejinan RoadHigh-Tech ZoneNanshan DistrictShenzen PR China 518057Tel 86 755 33966678Fax 86 755 33966700
Pulse North ChinaRoom 27042705Super Ocean Finance Ctr2067 Yan An Road WestShanghai 200336China
Tel 86 21 62787060Fax 86 2162786973
Pulse South Asia135 Joo Seng Road03-02PM Industrial BldgSingapore 368363
Tel 65 6287 8998Fax 65 6287 8998
Pulse North Asia3F No 198 ZhongyuanRoadZhongli CityTaoyuan County (32068)Taiwan
Tel 886 3 4356768Fax 886 3 4356823
Performance warranty of products offered on this data sheet is limited to the parameters specified Data is subject to change without notice Other brand and product names mentioned herein may be trademarks or
registered trademarks of their respective owners copy Copyright 2012 Pulse Electronics Inc All rights reserved
wwwPulseElectronicscomdownload3794G046
Series Platform Power RatingFootprint
(mm)
Height
(mm)
Primary Numbers
Turns
Primary DCR
(mOhms)
Secondary Number
Turns
Secondary DCR
(mOhms)PA08xxNL ER19 Gen 1 up to 140W 234 x 216 lt97 4 - 12 9 - 50 1 - 4 045 - 7
PH08xxNL ER19 Gen 2 Up to 160W 234 x 216 lt91 4 - 12 4 - 28 1 - 4 045 - 7
PH08xxCNL ER19 Gen 3 Up to 160W 247 x 216 lt96 3 - 12 35 - 28 1 - 4 05 - 7
PA09xxNL ER25 Gen 1 up to 250W 295 x 254 lt104 4 - 16 6 - 120 1 - 4 028 - 80
PH09xxNL ER25 Gen 2 Up to 300W 295 x 267 lt119 4 - 16 34 - 27 1 - 4 028 - 45
PH09xxCNL ER25 Gen 3 Up to 300W 305 x 270 lt126 2 - 16 18 - 27 1 - 4 038 - 46
PH10xxCNL ER28 Gen 3 Up to 500W 355 x 305 lt126 2 - 16 1 - 14 1 - 4 039 - 40
Gen 1 Gen 2 Gen 3Legacy PCB product line Flat Coil pin compatable with Gen 1 Pinned header amp flat coil
20 Further price reduction
Modified pad layout
Custom developmentbottom view
Product Overview Planar Transformer