When selecting transformers for your application, it’s important to know when to use high-frequency transformers over traditional low-frequency models. Typically, high-frequency transformers are best if you require a solution that’s more compact and efficient.
As a leading custom manufacturer of electronic components, MPS Industries specializes in selecting advanced materials and winding techniques for cutting-edge technologies, including high-frequency transformers. Learn more about the solutions to common design challenges and the specific technologies we support.
Design Challenges in High-Frequency Applications
Although high-frequency transformers offer certain advantages where traditional designs fall short, these common challenges must first be addressed during design.
Managing AC Winding Losses
When operating at high frequencies, conductor currents typically flow toward the surface in what is known as the skin effect. In addition, proximity effects occur when the magnetic fields from adjacent windings cause current to flow in eddy currents or other unintended patterns. These effects significantly increase resistance, resulting in AC winding losses.
With the help of Litz wire, high-frequency transformers can minimize AC winding losses. These wires consist of a woven bundle of fine, individually insulated strands that allow for more even current distribution.
Selecting Ferrite Cores for Minimal Core Loss
Another consideration is the use of ferrite cores to mitigate core loss. Ferrite cores are a popular option in high-frequency applications because of their combined cost-effectiveness and superior performance at higher frequencies, but their effectiveness depends on the exact frequency. Applications operating at frequencies exceeding 1 MHz might suffer from core losses using this material, so selecting the ideal core material will vary from application to application.
Insulation for High Voltage and Frequency
Transformers running at higher frequencies will also require more reliable insulation. One of the main reasons for this is the high temperature levels that high-frequency transformers achieve. As a result, more effective thermal management is needed to maximize the lifespan of insulation materials. Additionally, sufficient clearance must be maintained between the core and the windings.
Technologies We Support: Flyback, Forward, LLC, and More
At MPS Industries, we provide custom high-frequency transformers that support a range of converter technologies. Depending on your specific needs, we offer:
- Flyback transformers
- Flyback transformers for PoE applications
- Gate drive transformers
- Half bridge LLC resonant transformers
- High-power switching transformers
- Push-pull transformers
Applications in Industrial, Telecom, Medical, and Aerospace Electronics
There are plenty of applications for our selection of high-frequency transformers. For example, industrial applications for high-frequency transformer models include energy grid storage, power supplies, bus module drivers, and induction heating.
Main telecom applications are HF radio transceivers and satellite receivers, including solutions that support CCITT G.703 IEC 695 and other specific customer requirements.
High-frequency transformers in the healthcare sector must be medical-grade, which means that they exhibit very low current leakage, limited temperature rise, and other features that prevent failure or malfunction in critical patient applications. Potential uses include MRI equipment, CAT scan machines, and oxygen pumps.
The aerospace industry also relies on custom high-frequency transformers for applications such as aircraft lighting, entertainment, and searchlight systems. They are also widely used in unmanned aerial vehicles (UAVs) and exterior camera systems.
How MPS Can Provide You With the Right High-Frequency Transformer
If your application needs a dependable high-frequency transformer to maximize efficiency in a more compact design, the experts at MPS Industries can match you with the right model. Based on your specific application and converter technology requirements, we can supply a custom flyback, forward, LLC, switching, or other product that meets your unique needs.
When designing a custom transformer, we factor in several key elements to determine which design is best, including:
- Power requirements
- Energy losses
- Cooling requirements
- Skin and proximity effects
- Transformer ratings
- Safety requirements
- Switching topologies
Request a quote today to get started on a custom high-frequency transformer design.