CONTENTS Market Sectors Company Profile Planar Technology Product Range Overview Size 10 MAX 1kW Size 195 MAX 1.5kW Size 225 MAX 2kW Size 20 MAX 2kW Size 50 MAX 6.5kW Size 500 MAX 10kW Size 510 MAX 10kW Size 50 MAX 15kW Size 1080 MAX 0kW Size 1200 MAX 50kW Size 200 MAX 80kW Size 600 MAX 120kW Custom Design Thermal Handling/ Terminations Conventional Parts Other Products 2/ 5 6/7 8/9 10/11 12/1 1/15 16/17 18/19 20/21 22/2 2/25 26/27 28/29 0/1 2/ 5 6 7 Contact Us 8
MARKET SECTORS 2 Automotive Traction Aviation Defence Industrial Medical Communication
COMPANY PROFILE 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 s Advantages PLANAR TECHNOLOGY Planar s 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. High Efficiency (>99%) Low profile Lightweight (5g per W) Low Leakage Inductance Repeatability (Controlled Parasitics) Customised Terminations High Efficiency Multiple Multiple Winding Options Dimensional Accuracy kv, typical Reduced EMI
PRODUCT RANGE OVERVIEW 6 7 PRODUCT RANGE OVERVIEW s Size: 10 Size: 195 Size: 225 Size: 20 Size: 50 Size: 500 Size: 510 Size: 50 Size: 1080 Size: 1200 Size: 200 Size: 600 Output Power Frequency Input/Output Voltage Output Current 1kW MAX MHz MAX 500V MAX A MAX Page No. 1.5kW MAX MHz MAX 500V MAX 120A MAX 10/11 2kW MAX MHz MAX 600V MAX 150A MAX 12/1 2kW MAX MHz MAX 500V MAX 200A MAX 1/15 6.5kW MAX MHz MAX 750V MAX 00A MAX 16/17 10kW MAX 2MHz MAX 0V MAX 500A MAX 18/19 10kW MAX 2MHz MAX 0V MAX 00A MAX 20/21 15kW MAX 1MHz MAX 0V MAX 750A MAX 22/2 0kW MAX 1MHz MAX 0V MAX 0A MAX 2/25 50kW MAX 500kHz MAX 0V MAX 1200A MAX 26/27 80kW MAX 500kHz MAX 0V MAX 1200A MAX 28/29 120kW MAX 500kHz MAX 0V MAX 1200A MAX 0/1 8/9 s 10 225 195 50 500 50 1200 510 20 1080 10 1x10 600 200 Size: 10 Size: 195 Size: 225 Size: 20 Size: 50 Size: 500 Size: 510 Size: 50 Size: 1080 Size: 1200 Size: 200 Size: 600
8 9 0 1kW Max Power Parameters Specification Example SIZE 10 ER2 SIZE 10 10 Power Weight Dielectric Voltage Current 1kW 0G 2.5kV 500V 50A Full Bridge Half Bridge Boost Resonant Push Pull Buck Flyback 1x10 Voltage: - - - kvrms 20kHz-MHz PSU Output DC Voltage & Current Inductance Winding Current Winding Current Minimum Bus Voltage Maximum Bus Voltage to Ambient Temperature to to to 20W Full Bridge 12Vdc @ 20Adc (max) 9μH 25% 20A rms 20A rms 125kHz 9V 16V 1:2(+2 bias on primary & secondary sides) Heatsink -20 o C to +80 o C 0Vrms 500Vrms 500Vrms ER2 (Size 10) 2197-01 2,1 2,1 12 1 2 2,1 12 1 Bias Bias 2 i Pr i mary 0 0 Bias Bias 9 8 6 7 6 5 9 8 7
10 11 1.5kW Max Power Parameters Specification Example SIZE 195 Full Bridge Half Bridge Boost Resonant Push Pull Buck Flyback E8 1.5kW 60G 2.5kV 500V 75A SIZE 195 Voltage: - - - kvrms 20kHz-MHz PSU Output DC Voltage & Current Inductance Winding Current Winding Current Nominal Bus Voltage to Ambient Temperature to to to 80W Current Doubler 29.5Vdc @ 28Adc (max).8μh 25% 0A rms 1.A rms 250kHz 22V 1: Coldplate @ o C 2000Vrms 2000Vrms 2000Vrms 8 16 60 10 1x10
12 1 ER1 (Size 225) 20 2kW Max Power Parameters Specification Example SIZE 225 Full Bridge Half Bridge Boost Resonant Push Pull Buck Flyback ER1 2kW G 2.5kV 600V 75A SIZE 225 Voltage: - - - kvrms 20kHz-MHz 2kW Full Bridge ZVT PSU Output DC Voltage and Current 255Vdc @ 8Adc, 20Vdc @.75Adc Inductance 1.0mH 25% Winding Current 7.7A rms (max) Winding Current 5.5A rms (max) 250kHz Max Duty Cycle 0.1 Minimum Bus Voltage 75V Maximum Bus Voltage 80V to 10:1 Total Losses 1W (max) Liquid Cooled Baseplate Ambient Temperature -0 o C to +105 o C to 2700Vdc to 2700Vdc to 2700Vdc 1 16 1 1 5 66 55 10 1x10
1 15 2kW Max Power Parameters Specification Example SIZE 20 Full Bridge Half Bridge Boost Resonant Push Pull Buck Flyback E 2kW G 2.5kV 500V 75A SIZE 20 Voltage: - - - kvrms 20kHz-MHz 1kW Half Bridge PSU Output DC Voltage & Current 00V @ 2.5 max Inductance Winding Current 9.7μH 25% (provisional) 87A rms Winding Current 2.A rms khz Minimum Bus Voltage 2V Maximum Bus Voltage 8V to 1:6 Heatsink to 000Vrms to 2500Vrms to 2500Vrms E (Size 20) 80171 2 2 2 1 6 1 6 7 7 7 10 1x10 2 2
6.5kW Max Power Parameters Specification Example SIZE 50 Full Bridge Half Bridge Boost Resonant Push Pull Buck SIZE 50 Voltage: - - - 16 ER51 6.5kW 220G kv 0V 200A kvrms 20kHz-MHz 17 1.8kW Full Bridge PSU Output DC Voltage & Current 225Vdc @ 8Adc (max) Inductance Winding Current.8mH 25% (provisional).7a rms Winding Current 7.7A rms 80kHz Minimum Bus Voltage 90V Maximumm Bus Voltage to 17:11 Heatsink + Air Ambient Temperature 70 o C Max to 000Vrms to 2500Vrms to 2500Vrms ER1 ER1 (Size (Size 225) 225) 20 20 ER51 (size 50) 279-01 51 51 51 25 1 5 6 1 5 80 80 80 5 10 1x10
10kW Max Power Parameters Specification Example SIZE 500 Full Bridge Half Bridge Boost Resonant Push Pull Buck SIZE 500 Voltage: - - - 18 E6 10kW 00G kv 0V 500A kvrms 20kHz-MHz 19 7.6kW Full Bridge ZVS PSU Output DC Voltage & Current 58.2V / 10A Maximum Duty Cycle 0.9 inductance 1.mH 25% Winding Current 22.5A rms Winding Current 92A rms (each half) khz Minimum Bus Voltage 20V Maximum Bus Voltage 622V to 12:(2+2) Forced 2m/s Ambient Temperature -10 o C to 0 o C Insulation Working Voltage 600V rms to to 000Vrms 2000Vrms to 2000Vrms E6 (size 500) 12202 ER1 ER1 (Size (Size 225) 225) 20 20 E6 (size 500) 12202 105 105 65 0 65 6 65 0 105 1 1 6 6 1 6 5 10 1x10
10kW Max Power Parameters Specification Example SIZE 510 Full Bridge Half Bridge Boost Resonant Push Pull Buck SIZE 510 Voltage: - - - 20 ER6 10kW 00G kv 0V 00A kvrms 20kHz-MHz 21 PSU Output DC Voltage & Current Inductance Winding Current Winding Current Minimum Bus Voltage Maximum Bus Voltage to Ambient Temperature to to to 6kW Phase Shift Full Bridge 200V @ 0A dc 17.5μH 25% (provisional) A rms 29A rms 8kHz 18V 2V 1:12 Heatsink at 70 o C 000Vrms 2500Vrms 2500Vrms ER1 ER6 (Size 225) 500) 20 8016 ER1 (Size 225) 87 20 65 65 6 65 0 0 11 6 6 1 6 5 87 87 10 1x10
15kW Max Power Parameters Specification Example SIZE 50 Full Bridge Half Bridge Boost Resonant Push Pull Buck SIZE 50 10 1x10 Voltage: - - - 22 E102 15kW 1KG kv 0V 750A kvrms 20kHz-1MHz 2 12kW Full Bridge LLC PSU Output DC Voltage & Current 8V @ 250A max Inductance 5mH 25% Winding Current 29A rms Winding Current 20A rms 50kHz Minimum Bus Voltage 80 Maximum Bus Voltage 20 to 2: Heatsink Ambient Temperature -0 o C to +60 o C to 0Vrms to 0Vrms to 0Vrms ER1 (Size 225) 20 ER1 (Size 225) 20 102 102 102 175 175 1 1 6 6 1 6 5 175
2 25 ER1 (Size 225) 20 ER1 (Size 225) 20 175 0kW Max Power Parameters Specification Example SIZE 1080 E102 Double Full Bridge Half Bridge Boost Resonant Push Pull Buck SIZE 1080 10 0kW 1.5KG kv 0V 0A 1x10 Voltage: - - - kvrms 20kHz-1MHz 18kW Full Bridge PSU Output DC Voltage & Current 00V @ 20dc Peak Magnetizing Inductance 5.1mH 10% Winding Current 87A rms 50kHz Bus Voltage 500-700V Duty (pulsed power) 0. to 16:8 Clamped to Cold Plate Est. 0 Degrees C to to 000Vrms 2500Vrms to 2500Vrms 102 102 102 175 175 1 1 6 6 1 6 5
26 27 ER1 (Size 225) 20 E15 (Size 1200) 80156 50kW Max Power Parameters Specification Example SIZE 1200 Full Bridge Half Bridge Boost Resonant Push Pull Buck E15 50kW KG kv 0V 1200A SIZE 1200 Voltage: - - - kvrms 20kHz-500kHz 25kW Full Bridge PSU Output DC Voltage 200-00V Inductance Winding Current 12.mH 25% 5.2A rms Winding Current 62A rms 20kHz Minimum Bus Voltage 58V Maximum Bus Voltage 800V to 6:18 Clamp + Heatsink + air flow to 000Vrms to 2500Vrms to 2500Vrms 15 62 15 62 220 220 1 1 6 6 5 10 1x10
80kW Max Power Parameters Specification Example 280 280 SIZE 200 E15 Double Full Bridge Half Bridge Boost Resonant Push Pull Buck SIZE 200 10 1x10 Voltage: - - - 28 80kW KG kv 0V 1200A kvrms 20kHz-500kHz 29 5kW Full Bridge Voltage 600V Inductance 2.9mH Winding Current 75A Winding Current 75A 0kHz to 10: (5+5 / 5+5) Natural Air Cooled Ambient Temperature 65 o C Ambient to 000Vrms to 000Vrms to 000Vrms E15 E15 E15 Double Double Double (size (size (size 2000) 2000) 2000) 80175 80175 80175 E15 Double (size 2000) 80175 280 280 280 15 15 15 62 62 62 15 15 62 11 1 88 8 7 77 6 66 5 55
0 1 ER1 (Size 225) 20 120kW Max Power Parameters Specification Example SIZE 600 E15 Triple Full Bridge Half Bridge Boost Resonant Push Pull Buck 120kW 1KG kv 0V 1200A SIZE 600 Voltage: - - - kvrms 20kHz-500kHz kw Full Bridge PSU Output DC Voltage & Current 500Vdc @ 200Adc (max) Inductance 800-900μH Leakage Inductance <1μH Winding Current 1A rms Winding Current 200A rms 20kHz Minimum Bus Voltage 750V Maximum Bus Voltage 820V to 12:8 Heatshunts / Coldplate to to 000Vrms 2500Vrms to 2500Vrms E15 Triple (Size 600) 8009 15 15 62 62 10 10 11 6 6 1 6 5 10 1x10
CUSTOM DESIGN 2 CUSTOM DESIGN 150kW Planar Medical Planar 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 - 9 mm, Width - 75mm, Height - 72.5 mm Weight - 22.6kg A Planar with a continuous power rating of 6.5kW with short periods that require 12kW. The transformer is designed with 2 pairs of E6 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 kv @ 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 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 In operation s 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 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 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 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 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 Natural (Hot Spot Air) Blowing Air ms/sec (Hot Spot-Air) One Side Heatsink (Hot Spot - Heatsink) Two Side Heatsink (Hot Spot-Heatsink) 1.7 ºC/W 1. ºC/W 1.6 ºC/W 0.8 ºC/W 5 Just Some Of Our Terminations 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 Horizontal PCB Mounting Vertical PCB Mounting Bolted Connections Customised Extended Lead-Frames Bolted and Soldered Connections Power Soldered Leads Fly Leads Vertical PCB to PCB
CONVENTIONAL PARTS 6 7 OTHER PRODUCTS A World Of s Under One Roof On top of Planar s, Himag also offer a wide range of Wire Wound s, Choke Coils & Line Filters. Power Supply & Adaptors OEM & Turnkey Projects
CONTACT US 8 Tel: + (0) 152 722 51 Fax: + (0) 152 881 60 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 Scan Me www.himag.co.uk