High-Frequency 10kW Planar Power Transformer

High-Density Isolation Optimized for Laser Welding & Resonant Converters

🛠️ 1. Product Overview

This is a next-generation 10 kW high-frequency isolation transformer engineered using advanced Planar Transformer Technology. Operating seamlessly within an 80 kHz to 100 kHz frequency range, this series is specifically optimized for high-power, space-constrained systems such as industrial laser welding equipment, Dual Active Bridge (DAB) networks, and LLC resonant converters.

By replacing traditional wire-wound bobbins with stacked copper PCBs or flat copper ribbons, this planar transformer delivers an ultra-compact, low-profile design with an exceptional power-to-volume ratio. With a 700 VDC nominal input rating and a precision 1:1.07 transformation ratio, it provides robust, highly reproducible high-voltage isolation while drastically reducing structural weight and cabinet space.

🎯 2. Key Features

• Ultra-Compact Planar Design: Features a low-profile, flat-stack configuration that delivers superior power density, making it ideal for sleek, modular industrial enclosures where traditional transformers cannot fit.

• Optimized for Laser Welding Systems: Engineered to handle the intense, repetitive, dynamic pulse loads typical of high-precision fiber or Nd:YAG laser welding equipment without thermal degradation.

• Integrated Resonance Calibration: Features a tightly controlled leakage inductance (L_leak < 67uH). This allows the planar structure to double as the resonant inductor in soft-switching topologies, saving valuable PCB space.

• Excellent Thermal Performance: The flat, rectangular shape provides a significantly larger surface-area-to-volume ratio compared to traditional transformers, facilitating exceptional heat dissipation and lowering hot-spot temperatures.

• High-Voltage Capability & ZVS Optimization: Designed for input voltages up to 750 V. The magnetizing inductance (L_m 580uH) is precisely calibrated to facilitate seamless Zero Voltage Switching (ZVS), maximizing system-level efficiency up to 99%.

• Unmatched Parasitic Consistency: Because planar windings are chemically etched or stamped, manufacturing tolerances are near-zero. Every unit yields identical leakage inductance and parasitic capacitance, eliminating power supply tuning issues on the assembly line.

⚡ 3. Typical Applications

• Laser Welding & Cutting Equipment: High-power, compact embedded power modules for laser source power generation.

• Electric Vehicle (EV) DC Fast Chargers: Compact isolation stages for heavy-duty EV charging blocks.

• Energy Storage Systems (ESS): Space-saving bidirectional DC-DC conversion systems for industrial battery banks.

• Renewable Energy Inverters: High-density isolated DC-bus interfaces for solar grid-tie networks.

📊 4. Technical Specifications

Derived from strict matrix validation under peak thermal and electrical stress limits:

🤝 5. Why Choose Trafopsu?

• Professional Magnetic Engineering: At Trafopsu, we excel in pushing the boundaries of power density. Our planar transformers are simulated using advanced finite element analysis (FEA) to achieve perfect interleaving structures, virtually eliminating high-frequency proximity losses.

• Flexible Customization Framework: Do your laser power supply specifications require a specific footprint or custom integrated leakage (e.g., exactly 45uH or 60uH)? Trafopsu offers unmatched engineering flexibility. We can customize turn ratios, layer counts, cooling plates, and bus-bar termination layouts to drop straight into your existing hardware.

• Reliable Industrial Longevity: True to our promise—Professional · Flexible · Reliable—every planar unit undergoes rigorous quality assurance, including partial discharge testing and high-voltage isolation tracking, ensuring a stable, zero-maintenance lifespan on your production floor.

Need an exact 3D STEP Model or customized planar height adjustments?

Contact our engineering support desk at www.trafopsu.com to co-develop your next high-density power solution!