Switching Converter, SMPS Transformers

Part Number	Description / PDF	Quantity
B78304B1031A003 TDK EPCOS	XFMR DC/DC CONV SMD	162
B78304B1030A003 TDK EPCOS	XFMR DC/DC CONV SMD	0
B82805A943A250 TDK EPCOS	P100626 E6.3 SMT PUSH-PULL TRANS	29
B82802A0012A215 TDK EPCOS	TRANSFORMER FLYBACK 36-60V SMD	37
B82806D0060A240 TDK EPCOS	P300868 EFD20 POE TRANSFORMER	18
B78334B1033A003 TDK EPCOS	XFRMER DC/DC CONV SMD	1198
B82802A0030A220 TDK EPCOS	TRANSFORMER FLYBACK 36-60V SMD	0
B78304B1016A003 TDK EPCOS	XFMR DC/DC CONV SMD	0
B82802A0055A325 TDK EPCOS	TRANSFORMER FLYBACK 36-60V SMD	0
B78334B1018A003 TDK EPCOS	XFRMER DC/DC CONV SMD	0
B82806D0060A120 TDK EPCOS	P300870 EFD20 POE TRANSFORMER	50
B78307A2338A003 TDK EPCOS	AUXILIRY TRANSFORMER E10 SMD	268
B78334B1034A003 TDK EPCOS	XFRMER DC/DC CONV SMD	676
B82802A0055A225 TDK EPCOS	TRANSFORMER FLYBACK 36-60V SMD	0
B82805A0952A250 TDK EPCOS	P100724 E6.3 SMT PUSH-PULL TRANS	0
B82806D0060A050 TDK EPCOS	P300869 EFD20 POE TRANSFORMER	798
B82805A0773A250 TDK EPCOS	P100625 E6.3 SMT PUSH-PULL TRANS	539
B78307A2385A003 TDK EPCOS	AUXILIRY TRANSFORMER E10 SMD	279
B82802A0012A315 TDK EPCOS	TRANSFORMER FLYBACK 36-60V SMD	184
B82802A0030A320 TDK EPCOS	TRANSFORMER FLYBACK 36-60V SMD	0

Switching Converter, SMPS Transformers

1. Overview

Switching Mode Power Supply (SMPS) Transformers are critical components in power electronics systems, enabling efficient voltage conversion through high-frequency switching techniques. Unlike traditional linear transformers, SMPS transformers operate at frequencies typically above 20 kHz, allowing reduced size, weight, and improved energy efficiency. These components are essential for modern power management solutions in electronics, renewable energy systems, and industrial automation.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Discontinuous Mode (DCM) Flyback	Galvanic isolation, single-switch control	AC-DC adapters, battery chargers
Continuous Mode (CCM) Flyback	Higher power density, lower ripple current	LED drivers, industrial power supplies
Forward Converter	Efficient for medium power levels, requires reset circuit	Server power supplies, telecom equipment
Push-Pull	Balanced magnetic utilization, high efficiency	High-end audio amplifiers, welding machines
Half-Bridge/Full-Bridge	High power capability, symmetrical switching	Electric vehicle charging, solar inverters

3. Structure and Components

Typical SMPS transformer construction includes:

Core materials: Ferrite (Mn-Zn or Ni-Zn), Powdered Iron, Amorphous alloys
Winding configuration: Primary/secondary windings with optimized turn ratios
Insulation system: Bobbins, tape insulation, and potting compounds
Termination: Tin-plated copper leads or surface-mount pads
Shielding: Electrostatic shields for EMI reduction

4. Key Technical Specifications

Parameter	Importance
Input Voltage Range	Determines compatibility with power sources
Output Power Rating	Defines maximum energy transfer capability
Switching Frequency	Impacts size, efficiency, and EMI performance
Turns Ratio Accuracy	Affects voltage regulation precision
Isolation Voltage	Ensures safety and dielectric strength
Efficiency (Typical >90%)	Reduces thermal management requirements
Operating Temperature	Determines reliability in harsh environments

5. Application Fields

Major application sectors include:

Consumer Electronics: Mobile device chargers, laptop adapters
Industrial: Motor drives, PLC power supplies, test equipment
Telecommunications: Base station power systems, optical network equipment
Renewable Energy: Solar inverters, energy storage systems
Automotive: On-board chargers (OBC), DC-DC converters
Medical: Isolated power supplies for diagnostic equipment

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
TDK-Lambda	PWM Switching Transformer	High-density design, 150kHz operating frequency
Coilcraft	XEL60xx Series	Ultra-low profile, 25A saturation current
Pulse Electronics	PA5477NL	Integrated EMI filtering, automotive qualified
Bel/Signal Transformer	125-2011-F	Medical-grade isolation, 4kV withstand
Delta Electronics	TMA-101-01	High-efficiency (94%), 1kW power rating

7. Selection Guidelines

Key considerations for optimal selection:

Power requirements (continuous vs peak load)
Switching frequency compatibility with controller ICs
Thermal management capabilities
Creepage/clearance distances for safety certification
Cost-performance trade-offs
Package dimensions and mounting requirements
Compliance with standards (UL, IEC, AEC-Q)

8. Industry Trends

Current development directions include:

Miniaturization through higher operating frequencies (>1MHz)
Integration with wide-bandgap semiconductors (GaN/SiC)
Advanced nanocrystalline core materials
AEC-Q qualified components for automotive electrification
Smart transformers with embedded sensing
RoHS-compliant, halogen-free construction

Market forecasts indicate 8.2% CAGR through 2028, driven by 5G infrastructure and renewable energy adoption.