MPS Industries, Inc. - Press
5/2019 Increasing Output Power Yield with Forward Converters
Forward converters share similar energy efficiency and appearance qualities with flyback and half-bridge converters, but they can be distinguished by their higher output power yield (up to 200W). These DC-to-DC converters operate through the integration of a forward transformer (to raise or decrease output voltage) and a filter inductor (to moderate current consistency and store energy).
For applications where a high output current is required, forward converters are an optimal fit.
Forward converters can be applied to a wide range of industries and their power systems, including:
- Off-line supplies
- Solar power systems
- Hybrid charging techniques
- Computer power supplies
- Aerospace power supplies
The MPS engineering team has created a comprehensive guide to the various types of forward converters and their applications - check it out below:
4/2019 Advanced Circuit Isolation with Flyback Transformers
Flyback transformers (also known as line output transformers) are used in high-efficiency isolated power supplies and provide excellent circuit isolation, the capacity for multiple outputs, and the potential for both positive and negative output voltages.
Because of their uncomplicated design, versatility, and low cost, flyback transformers make a great choice for power supples <150W.
Flyback transformers can be applied to and benefit a diverse range of applications, such as:
- DC-DC and AC-DC power supplies
- High voltage power supplies
- Battery charging
- Solar microinverters
- LED lighting
To learn more about flyback transformers and how they work, check out our application notes here:
3/2019 Power & Voltage Benefits of Buck-Boost Converters
Buck-boost converters make it easy to manage voltage for applications that involve a wide variety of input voltages
As their name may imply, buck-boost converters join together elements of buck converters and boost converters in one circuit.
When the power source reaches a higher voltage than the input voltage, the buck converter kicks in to reduce it (this is why they're also called step-down converters). On the other hand, if the power source voltage drops below input voltage, the boost (or step-up) converter will raise the voltage back up.
Some of the many applications that benefit from buck-boost converters include:
- Self-regulating power supplies
- Battery power chargers & systems
- Hybrid electric circuits
- Solar power systems
- Power audio amplifiers
To find out more about how buck-boost converters work and their topologies, check out our application notes below.
2/2019 Custom Balun Transformers for Impedance Signal Matching
The term "balun" joins together "balanced" and "unbalanced," just like its function as a transformer.
Specifically, balun transformers send signals to and from an unbalanced impedance input, such as a coaxial cable, and a balanced impedance output, such as twisted pair cables.
Balun transformers are commonly used within broadband frequency applications, and are an excellent solution for long distance communications as well. Some additional uses of a balun transformer:
- Achieving maximum power transfer through impedance matching
- DC isolation for high voltage protection and improving noise immunity
- Step up or step down of signal amplitude
To learn more about our custom balun transformers, contact us today, or check out our application and design resources below:
1/2019Phase Shift Full Bridge (PSFB) Transformers
These days, many power applications such as AC-to-DC power supplies, battery chargers, and renewable energy applications require high efficiency combined with high power density. Phase shift full bridge (PSFB) transformers are commonly used in high power, energy storage-type applications and have the advantage of lower costs and higher efficiency.
Customers looking to build a higher efficiency converter often benefit from PSFB transformers.
We customize our high efficiency PSFB transformers and resonant inductors according to our clients' specific requirements; the resulting components feature low losses for high current and high frequency.
Some general features of our PSFB transformers:
- Designed to handle power requirements of 20KW and higher
- Mounting options customized precisely to requirements
- Available with thermal potting for cold plate mounting
To learn more about our custom-engineered PSFB transformers, contact us today, or check out our blog about how PSFB transformers work:
12/2018 Custom Magnetic Solutions for Industrial Applications
Compressor motors, HVAC, and commercial refrigeration all have one thing in common: dynamic requirements that benefit from durable magnetic components - especially during the high-demand holiday season.
For exceptional performance even through continuous operation, extreme environmental conditions, and high temperatures, you can rely on our high quality transformers and conductors.
At MPS Industries, we offer a full line of standard and custom transformers for industrial applications such as those featured in our "Magnetic Components for the Industrial Market" YouTube video.
We conduct testing at every stage of production to guarantee that our components are an optimal, reliable fit for your equipment. To shee how the MPS Industries team can design and custom-engineer a component for your project, contact us today or check out our industrial application capabilities here:
11/2018 Maximize Your Electric & Hybrid Vehicle Power!
With Tesla's developments rolling out and the growing road presence of electric and hybrid vehicles, the question of whether they will be able to generate and handle a high power load will determine their success.
Our Power Transformers
Upgrades to hybrid and electric vehicle safety systems, on- and off-board battery charging, cabin lighting, and other components call for efficient power management. Designed to hold up against these increased power demands, MPS Industries' power transformers feature:
- A low profile, surface mount design
- Zero Voltage Switching (ZVS) for high-frequency and high-voltage operations
- High Q Value and Low Leakage Inductance
- Great temperature stability, ensuring a small variation in inductance
- AEC-Q200 qualifications for automotive applications
Our High Current Fixed Inductors
Typical extreme heat and voltage conditions generated by modern power transmission systems can drain electrical energy, and fast. Our high current fixed inductors seamlessly integrate within hybrid and vehicle systems and provide:
- Superior thermal management and heat dissipation
- Significantly reduced size and weight compared with conventional toroid designs
- A flat wire coil for minimizing losses at a high frequency
- High current induction in a compact size
- High energy storage capabilities
To learn more about the hybrid and electric vehicle applications of our power transformers and high current fixed inductors, check out our latest blog post here.
04/2018 Announcing the Launch of MPS CCFL Transformers
Announcing the Launch of MPS CCFL Transformers
In need of CCFL (Cold-Cathode Fluorescent Lamp) Transformers for your products?
Recently, we've been receiving an influx of calls regarding our CCFL Transformers. While other power management technology companies have discontinued their lines, there is still strong market demand for these transformers.
As some companies migrate over to strictly LED technology, the engineers at MPS are aware that others have not, creating the urgency for CCFL Transformers for your current product lines needs.
MPS offers our full line of CCFL Transformers optimized for your needs.
Today, industries still currently in need of fluorescent lighting capabilities include automotive, industrial, medical, military, aerospace, telecom, and consumer electronics.
- LCD backlight applications
- TFT matrixes
- Aquarium lighting
- Medical instrumentation
- Test equipment
- & more
Features of our CCFL Transformer Designs and Capabilities
- Can deliver output power from 2.5 to 14 Watts
- Can be designed through-hole or surface mount
- Ferrite material
- Storage Temp -40 to 85C
- Operating Ambient 0 to 70C
- Low profile
MPS also offers custom-made options for your specific transformer design needs. For more on our transformer product lines, you can request information below or call one of our knowledgeable representatives currently on standby.
03/2018 Optimize Your SMPS with MPS
We Know High-Power Conversion Efficiency
High-power conversion efficiency is important in your SMPS design, especially in your DC-DC switching converters.
MPS Industries, Inc. is a supplier of magnetics for SMPS. We will work with you to select and design the most optimized components for your needs. This includes various transformer topologies, output filter inductors and chokes.
An Inductor Example for High-Frequency SMPS
In high-frequency SMPS, you may consider using an inductor made of powdered iron or ferrite, such as our P11T80B (imaged above). Powder core has higher core loss with soft saturation, while ferrite saturated more sharply but has improved core loss
A Recipe for Success: MPS on SMPS
With our skilled team, you don't have to worry about big losses in power or size reduction. Upon request, we can provide the loss data for you to determine the estimated efficiency of your SMPS. We look forward to helping you achieve the highest performance level on the market today!
12/2017 Custom Inductor Solutions
MPS' HEW High Current Inductors are the most comprehensive on the market today!
Options range from our standard smaller surface mount 30A inductors (HWIA2918S series) to larger customized chassis-mounted inductors, capable of handling up to 1000A.
Our HEW inductors have less skin effect at high current for high frequency applications, as well as low EMI due to the clean simple winding, lower inter-winding capacitance and less capacitive losses (compared to multi-strand round wires).
Depending on your requirements, MPS might offer traditional round wire for consideration. If designing for a resonance application, MPS can design using high-strand count litz wire molded to MW-79C (3000V) too.
Think Big: 100A-1000A Inductor Capabilities & Customization Single or 3-Phase, Coupled Inductors for your design:
- Potted with thermally conductive material for mounting to cold plate/heat sink or open type for convection/forced air cooling
- Customized mounting and connections for hassle-free integration into customer system
- Traditional type round wire and copper foil design
- Can design to handle capacity up to 1000A
Using modular design, our inductors can be connected in parallel for increased current capacity or in series for increased inductance!
About MPS Industries, Inc.
MPS makes the most dense, compact, and versatile range of HEW inductors to meet your electrical and mechanical needs. Our engineers work closely with you to create your design based on your electrical and mechanical requirements for your specifications.
If you need high current inductors, we can help! Speak with an MPS representative.
Reduce Your Lead Time with the HWI57A2 and H1300 High Current Inductor Series
Looking for a high-power inductor for your initial board evaluation? Have one of our models in hand to quickly test your board instead of waiting for a full custom design.
Avoid NRE's, any tooling, and long lead time with our ideal-for-your-requirements HWI57A2 and H1300 series. Their modular design allows you to connect each in series or in parallel for higher inductance or current.
HWI57A2 & H1300 Series:
- Units are semi-customizable
- Lead connections can be optimized
- Thermal potting available in 1,2, or 3 w/mk depending on requirements & targeted cost
- Units arrive ready to bolt down, connect, and install
- No need for an NRE
- Shorter lead times than other fully customized inductors
Simplify Your Power Conversion Process, Easily Manage Power Conversion Applications
Efficiency, cooling, and packaging are key players in power conversion applications. We will work closely with your team to provide a nice, clean, easy-to-mount packaging solution, to make your mechanical and electrical engineers happy.
- Packaging optimization based on cooling method and mounting configuration
- Heat sink integration (per request)
- Can provide 3D STEP files
- Low-cost CNC machine cutting resources for enclosures/brackets for prototype purposes
- Embedded temperature sensors (per request)
- Low or no NRE
- Domestic engineering support (in both CA and TX)
- Domestic and off-shore manufacturing and prototyping abilities
- Ability to package "drop-in" solutions for standard inductors, such as:
- The HWI4427 series or The HWI4434 series
Customizable Hardware & Mechanicals For Your Magnetic Solutions
MPS is your complete magnetics solutions provider. We work to make your life as easy as possible when it comes to magnetics.
Our design engineers aim to optimize MPS products to get the best combination of performance and cost to suit each application.
That is not just limited to electrical engineering. A big part of it is customizing the mechanicals and hardware too. MPS facilitates electromechanical and thermal designs and can provide STEP files for your mechanical team.
Examples Of Hardware & Mechanicals We Can Do For You
- "Open-type" mounting
- Best for convection cooling
- Lower Cost
- "Closed-type" mounting
- Uses thermal potting + TIM (thermal interface material or gap pad)
- Best for mounting to cold plate or heat sink
- Great for applications with critical shock and vibration requirements
- Option of PCB cut-out version
- Low profile for board-level magnetic component
- Variety of connection options
- Bus bars, flying leads
- Vertical or horizontal mounting
- Temp sensors/thermocouple and thermal switches
How MPS Chooses The Right Wire For Your Application Needs
- HEW (helical edge wound)
- As pictured in all 3 images
- Rated for 200C
- Transformers: option of combination/ interleaving flat wire and litz wire for lower leakage
- Flat aluminum wire
- Good for cost/weight for bulk orders, ex: aerospace applications
- High-strand count litz wire
- Molded to MW-79C (3000V) or higher voltage
- Resonance application
- Option of PCB cut-out version
- Low profile for board-level magnetic component
Contact Us For Your Custom Product Requirements Today
Are you looking for custom components for your specialty applications? MPS has the manufacturing capabilities and expertise to design it. We construct custom and semi-custom high-performance magnetics for automotive, aerospace, industrial, medical, defense, military, telecom and consumer electronics.
MPS: No Stranger to Quality & Efficiency in High-Power Magnetics
MPS is always looking to push the envelope when it comes to magnetic designs. Our goal is to provide our customer with the most optimized solutions. When developing our high power standard product line, we strived to improve both the efficiency and heat dissipation of our parts. MPS engineers understand that quality, compact size, and low DCR are crucial requirements for our customer base. As with our other HEW Inductors and technology, our HWI34 series is no exception in addressing all of those needs.
A Closer Look at Our HWI34 Series
- Low profile, small footprint, compact form
- Inductance Range 4.7 uH to 29uH
- Exceptionally low DCR
- Great heat dissipation
- True 45-55 Amp wire handling capacity
- Powered cores with distributed gap for soft saturation
- For high-temperature environments - up to 125°C ambient (max temp 180C)
- Higher current available
- Different mounting available
Contact Us for Your Custom Product Needs
When you're looking for a custom component for a specialty application, remember that MPS Industries has the manufacturing capabilities and expertise to design it. We construct custom and semi-custom high-performance magnetics for automotive, aerospace, industrial, medical, defense, military, telecom and consumer electronics. To learn more, view our custom designed magnetics page for additional information.
If you need magnetic components, we can support you.
Contact us today to speak with an MPS representative.
HEW™ Single Phase AC/DC Reactors: A Recommended Alternative
MPS Industries, Inc. introduces our HEW (Helical Edge Wound) Single Phase AC/DC Reactors, customized and optimized for your specific reactor needs. These reactors are a recommended alternative for amorphous/lamination core and copper foil wound reactors.
Highlights and Advantages to this Alternate Design Approach:
- Designed with distributed gap powder cores = minimum gap loss
- No concentrated hot spot on the winding due to fringing flux from the gap
- Soft saturation
- Low audible noise level
- Clean single layer HEW winding
- Single layer winding = better heat dissipation
- Machine-wound = less labor intensive, more cost effective
- Lower losses (for AC), proximity effect, and capacitance vs. copper foil counterpart
- Recommended for requirements of >20A
- Can be provided in brackets (horizontal or vertical) for air-cooled applications, or potted for cold-plate
- Mounting optimization available based on requirements, preferred orientation and cooling method
Contact Us for Your Reactor and Custom Product Needs
Imaged above are custom products. If you are currently using a Single PhaseLamination/Amorphous reactor, are looking for AC and DC reactors, have a new requirement or are looking for custom products, please contact us today to speak with an MPS representative!
Surface Mount High Current HEW Inductors
Gardena, CA (July 1st 2016) - MPS Industries' HWIA2918S Series offers a High Current HEW Inductor in a surface mount, low-profile, compact form.
Maximum height for these inductors is 18mm and the package includes a dummy 3rd pin for extra mounting stability. The HWIA2918S series is constructed using wire with true 30 Amp handling capacity.
The standard series inductance ranges from 3.3 microhenries up to 33 microhenries and very low DCR.
High Density Inductors for 1U Power Supplies
Gardena, CA (May 1st 2016) - MPS Industries' HWI4427 and HWI4434 series of Helical Edge Wound (HEW) inductors is the lowest profile and highest current density package size in the industry, making them perfect for very high density 1U power supplies above 2kW.
These inductors are available with height as low as 27mm and in a variety of mounting options, including horizontal, vertical, and with additional mounting hardware for added support. The HEW flat wire coil minimizes losses at high frequencies and can handle up to 160 Amps per inductor (with cooling) and can be paralleled to meet 300 Amp requirements.
Using different materials available, MPS is able to configure the inductors for various magnetic applications such as PFC, DC output, AC input, or Boost in the same low profile package. We offer a wide variety of standard High Current Inductors with ability to customize per client specifications as well.
- Very high power density rack mount or benchtop 1U power supplies
- Electric Car (EV) applications
- EV Wireless Charging
- High Power PV Micro-Inverters above 1kW
Flat Wire High Current Inductors
Gardena, CA (March 1st 2015) - MPS Industries, Inc. continues to add to our growing line of Flat Wire High Current Inductors. Our new HWI4427 and HWI4434 Series range from 5 microhenries to 91 microhenries and rated current up to 51 amps.
These inductors provide high current handling capacity in a compact package with superior thermal management and heat dissipation. Both series offer a variety of mounting configurations including vertical, horizontal, thru-hole, surface mount, and more. A full range of custom designs is also available upon request.
High Current Planar Transformers
Gardena, CA (November 1st 2014) - MPS Industries introduces a new series of High Current Planar Transformers using our flat wire, helical winding construction. The planar design yields high efficiencies in a compact, low profile package size. Additionally, by incorporating the flat wire, helical wound coils, we are able to offer a wide selection of custom configurations with considerably shorter design lead times and lower startup and production costs than traditional planar designs. The coil structure also allows for excellent heat dissipation and high current handling capacity.
Our HP30 Series consists of Full Bridge Transformers with rated power from 500W to 1000W. A full range of custom designs is also available upon request.
Flat Wire Inductor Modules for Inverter Systems
Gardena, CA (July 1st 2014) - MPS Industries is releasing a line of flat wire, high current inductor modules for inverter systems. The new H1300 Series and HWI57A2 Series inductors are ideal for use in PV Inverter, String Inverter, and Bidirectional Inverter applications.
The flat wire coil construction offers superior thermal management and heat dissipation, which results in superior performance and reliability. The inductor modules are also potted in aluminum enclosures with thermally conductive potting material to further enhance thermal management, prevent vibration issues, and allow for easy mounting.
The H1300 Series features current rating over 100 Amps and the HWI57A2 Series features current rating over 200 Amps. Custom design is available up to 500 Amp current for inverter systems 20kW and up. Click here for full press release.
Magnetic Epoxy Shielded Inductors
Gardena, CA (March 1st 2014) - MPS Industries introduces a new line of surface mount power inductors featuring magnetic epoxy shielding as a lower cost alternative to conventional ferrite shielded inductors. By replacing the traditional ferrite shield with a magnetic epoxy resin, we are able to significantly reduce both material and labor costs, as well as improve production lead times.
With regards to performance, the coupling factor (K) of the magnetic epoxy inductors falls somewhere between that of ferrite shielded and unshielded inductors. These new inductors are offered with the same or similar overall dimensions and footprint as their ferrite shielded and unshielded counterparts and so provide a nice alternative, bridging the gap between the two.
Ideal applications for these lower cost inductors include DC/DC converter, computer, LED lighting, and various industrial and consumer electronics products.
Half Bridge LLC Resonant Transformers
Gardena, CA (October 1st 2013) - In today's energy conscious environment, electronic product manufacturers are focused on efficiency, as they are faced with the difficult task of continuously improving performance while consuming less power. To assist our customers with their energy conservation efforts, MPS Industries introduces two new LLC Resonant transformers (P6503 and P6504) that are designed to provide very high efficiency and very low power loss.
These transformers are ideal for use in conjunction with an upstream PFC circuit in applications that require maximum efficiency, such as the LLC resonant converter. The LLC resonant topology allows for zero voltage switching (ZVS), resulting in drastically reduced switching losses and significantly improved efficiency. MPS Industries' new half bridge LLC resonant transformers are ideally suited for such applications, and our team of highly experienced engineers are also ready to work with our customers to design custom solutions to meet individual needs.
MPS Offers Standard & Custom PFC Inductors
Gardena, CA (August 1st 2012) - MPS Industries proudly designs and manufactures a wide range of standard and custom power factor correction (PFC) inductors for various applications. Our skilled engineers work closely with our customers to find a PFC inductor that will fit their requirements. We can design our parts with customized inductance ranges, power ratings and current values to offer greater levels of flexibility to our customers. Our high power inductors are available in several mounting options and are competitively priced.
We have recently introduced two new series of PFC inductors into our product line. Our P1900-series and P191-series toroidal PFC inductors are constructed with high flux materials for high current applications that require low loss at high frequencies to address the emerging global mandate on increased PFC performance. These low core loss inductors are designed for consistent performance, low EMI emissions, high efficiency and high saturation flux density with a significant reduction in size and weight.
MPS Develops Planar Transformers Product Line
Gardena, CA (January 10th 2012) - MPS Industries has developed six new series of planar transformers and one new series of planar inductors into their product line in order to provide highly efficient components for applications that have space, weight and/or height restrictions.
MPS's low profile planar magnetics offer very low leakage inductance and low core loss without compromising performance. With the use of an optimized core, advanced winding geometry and interleaving technology, these transformers have a high power density of 600 watts per inch, excellent heat dissipation and outstanding repeatability and reliability. Planar magnetics offer cost-effective alternatives to traditional magnetic solutions.
MPS's planar transformers are ideal for many applications, including automotive, medical, military and aerospace, telecom, high switching frequency power supplies, high current DC/DC converters and more.