High-Frequency Transformer Design

Designed Around Your Power Conversion Requirements

A high-frequency transformer is not simply a turns-ratio device. Its electrical, magnetic, thermal and mechanical characteristics must work together with the converter topology.

HY MFG designs custom high-frequency transformers for power electronics applications, starting with the operating requirements of the complete power conversion system.

We consider:

  • Input and output voltage
  • Output power
  • Switching frequency
  • Converter topology
  • Duty cycle
  • Isolation requirements
  • Operating temperature
  • Efficiency targets
  • PCB space and mechanical constraints

The objective is not simply to make a transformer that works.

It is to develop a magnetic component that works reliably within the complete converter system.

Our Transformer Design Process

1. Define Electrical Requirements

We begin with the fundamental operating conditions:

Input → Output → Power → Frequency → Topology → Isolation

These parameters establish the initial design envelope.

2. Select the Magnetic Structure

Core geometry, effective magnetic area, window area and magnetic material are evaluated according to the operating frequency and power level.

The selected core must provide sufficient magnetic capability while maintaining appropriate loss and thermal margins.

3. Develop the Winding Design

The winding structure is optimized for:

  • Turns ratio
  • Current density
  • Leakage inductance
  • Parasitic capacitance
  • Insulation
  • Copper loss

Winding construction is especially important at higher frequencies because AC resistance can become significantly different from DC resistance.

4. Evaluate Loss and Temperature

Transformer losses include:

Core Loss + Copper Loss + Additional AC Losses

The design is evaluated against the expected operating temperature and thermal environment.

5. Prototype and Validate

Engineering samples are produced and tested against the agreed electrical and mechanical specifications before production release.

Designed for Different Power Topologies

HY MFG supports custom magnetic designs for:

  • Flyback
  • Forward
  • Push-Pull
  • Half-Bridge
  • Full-Bridge
  • LLC resonant converters
  • Other custom topologies

The transformer design is developed according to the characteristics of the specific topology rather than using a one-size-fits-all approach.

Engineering Input

For a design review, customers can provide:

  • Schematic
  • Datasheet
  • Existing transformer
  • Transformer drawing
  • Electrical specifications
  • PCB layout
  • Application requirements

Even if the transformer specification is not complete, HY MFG can review the available information and identify the key parameters required for development.

Have a transformer design requirement?

Request an Engineering Review

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