High Power SMPS Transformers and Inductors

1kW PC Mount transformer

Shaped Foil Inductor (319 Series)

WCM’s 319 series inductors are designed for use in buck boost (differential) circuits. Using an improved generation of Shaped Foil Technology, this inductor series has lower core and winding losses than competing products, especially at frequencies over 10 kHz and ripple current magnitudes of 5% and higher. The 319 series is an industry leading low cost, high performance inductor. **patent pending on the winding technology used in this design.

Power Inductors (320 Series)

WCM’s 320 series inductors are designed for use in buck boost (differential) circuits. Using an improved generation of Shaped Foil Technology, this inductor series has lower core and winding losses than competing products, especially at frequencies over 10 kHz and ripple current magnitudes of 5% and higher. The 320 series is an industry leading low cost, high performance inductor
1kW PC Mount SMPS transformer

500 watt to 5 kW SMPS Transformers

West Coast Magnetics’ new WCM410-88,-70,-60,-50 series raise the bar for high power switch mode transformers. This new series was designed in order to achieve 50% more power density than other geometries currently available on the market, without sacrificing isolation. The core and bobbin are also suitable for safe UL/CSA/VDE coupling with medical grade isolation standards.

Power inductors designers are having to accommodate higher rms and ripple current values at frequencies as high as 500 kHz.. Technical trends in power inductors include higher power levels which translate to higher current carrying capability, higher frequency of operation, and higher ripple currents.  Packaging trends include smaller size and higher power density, and the use of higher temperature materials as a result of higher operating temperatures.

Technical trends with transformers include higher power levels and higher frequency of operation.  Design state of the art now would be a 10 kW transformer operating at 250 kHz.  At lower power levels frequency can be up to 1 MHz.

 As a consequence of the higher frequency, the parasitic properties (leakage inductance and capacitance) are becoming more important, and are often part of the customer’s specification.  The use of resonant circuit topologies, and circuits which combine inductive filtering with voltage transformation in a single device are also driving a new set of technical requirements for transformers.

Magnetic Cores

In response to a need for a new generation of magnetic cores with higher performance for switch mode power supply applications, we have developed a number of new proprietary magnetic cores.   They are low profile, PC mount packages with very low loss ferrite cores which have unprecedented power density.   The high power package will handle up to 10 kW at 250 kHz.  The lower power packages are designed to be used at frequencies up to 2 Mhz.

Power Inductors

Through our collaboration with the Thayer School of Engineering at Dartmouth we have developed new patented technology for inductors that are designed for the next generation of medium to high power switch mode power supplies.  This patented technology features windings which exhibit both very low AC and very low DC resistance, as well as low core losses.  We have also released new standard product inductors based on this new technology.

Power Transformers

We believe the next generation of switch mode power supply transformers will need to operate in the frequency range of 500 kHz to 2 MHz.  We are working with the Thayer School of Engineering at Dartmouth to develop technology for low loss windings in this frequency range.

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