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PQ65 12kW+ High-Power Automotive-Grade HF Isolation Transformer
PQ65 12kW+ High-Power Automotive-Grade HF Isolation Transformer
| Model： | PQ65 |
| Ae(mm2) : | 597 |
| Ref.Power: | 10 – 12 kW |
Product Description
📌 Product Overview
This high-frequency isolation transformer is engineered specifically for the most demanding operating conditions (Worst Current Case) in EV Bidirectional On-Board Chargers (OBC / V2G), high-power Energy Storage Systems (ESS/PCS), and Dual Active Bridge (DAB) / CLLC resonant topologies. Featuring a symmetrical 1:1 turns ratio, a high magnetizing inductance of >6.0 mH, and exceptional tolerance against intense high-frequency harmonic currents, this transformer can reliably handle an AC ripple current up to 23 A at 100 kHz. It maintains ultra-low core loss and minimal temperature rise, making it an ideal isolation solution for next-generation, high-power-density power electronics.
⚡ Key Electrical Specifications
| Parameter | Technical Specifications | Notes / Test Conditions |
| Turns Ratio | 1 : 1 | Optimized for bidirectional, symmetrical power flow |
| Magnetizing Inductance | > 6.0 mH | High-inductance design to minimize no-load reactive excitation current |
| Max Primary Peak Current | 21 A | Excellent transient anti-saturation capability |
| Max Primary RMS Current | 16 A | Continuous full-load operating current with ultra-low copper loss |
| Max Primary Magnetic Flux | 3200 µV·s | High volt-second margin to prevent magnetic saturation |
| Saturation Flux Density Margin | < 80% | Ensured safety under high temperatures (100°C–120°C); eliminates thermal saturation risks |
📊 Harmonic Current Content Tolerance
Engineered with a proprietary winding architecture, this product effectively neutralizes severe skin and proximity effects induced by hard-switching harmonics.
100 kHz -> 23 A (Primary switching harmonic band)
300 kHz -> 2.4 A
500 kHz -> 0.73 A
🛠️ Technical Highlights & Premium Craftsmanship
1. High Ripple Tolerance via Advanced Litz/Served Wire Winding
Handling a massive high-frequency alternating current of 23 A at 100 kHz would cause conventional solid copper wire to fail due to extreme skin and proximity effects, leading to thermal runaway. We utilize custom-engineered multi-strand served Litz wire (e.g., 0.07mm series) precisely twisted together. This maximizes the effective high-frequency conduction surface area, cutting high-frequency eddy current losses by over 75% and guaranteeing ultra-low AC resistance (ACR) across all operating frequencies.
2. Automotive-Grade Anti-Saturation Margin (Bsat < 80%)
In enclosed automotive charging environments or densely packed industrial cabinets, the saturation flux density (Bsat) of magnetic cores deteriorates sharply as temperatures rise. This transformer strictly adheres to a conservative design margin where the operating flux density is kept below 80% of Bsat. Paired with premium high-power Mn-Zn ferrite materials (such as the DMR95 series), the core exhibits a negative power loss temperature coefficient between 80°C and 120°C (meaning losses decrease as the core reaches its nominal operating temperature), completely eliminating the risk of thermal breakdown.
3. >6.0 mH High Inductance & Ultra-Low No-Load Loss
By using premium core materials characterized by high initial permeability and ultra-low hysteresis loss, the >6.0 mH magnetizing inductance successfully suppresses reactive excitation current to the absolute minimum, even under 100 kHz high-frequency switching. This dramatically minimizes standby and light-load power consumption, helping your power supply system seamlessly comply with strict efficiency standards like Energy Star or 80 PLUS.
4. Optimized Air Gaps & Enhanced Acoustic/EMI Shielding
To address the mechanical magnetostriction and high-frequency acoustic buzzing commonly caused by large (alternating) currents, we incorporate precision air-gap placement and high-insulation encapsulation halves. This construction effectively eliminates localized hotspots caused by leakage flux perpendicularly penetrating the windings while dampening acoustic vibrations well below ambient noise levels.
🎯 Typical Applications
Electric Vehicles (EV/HEV): 7kW / 11kW / 22kW bidirectional On-Board Chargers (OBC) and Vehicle-to-Grid (V2G) systems.
Renewable Energy & Storage (ESS/PV): Bidirectional isolated DC-DC converters in Energy Storage Power Conversion Systems (PCS) and solar micro-inverter isolation stages.
Bidirectional Power Topologies: Dual Active Bridge (DAB) and CLLC / LLC resonant converters.
Premium Industrial Supplies: High-frequency inverter welding machines and ultra-high-power telecom server power supplies operating under harsh field conditions.
📐 Engineering & Customization Services
Backed by an experienced electromagnetic simulation team and automotive-grade production lines, we provide rapid prototyping and customization services. We can fine-tune the wire gauge, turn count, core geometry, and material grade to match your specific volt-second requirements, space constraints, or harmonic profiles.
