Hybrid planar transformers in low cost small packages

Vishay has a new series of 250W full-bridge hybrid planar transformers for avionics, industrial control, and alternative energy control applications. Featuring a unique winding structure, TPL-2516 series devices provide a cost-effective solution compared to traditional planar transformers while featuring smaller packages, improved performance, and easy customization. The winding structure of the devices released today allows for a greater copper fill factor than traditional planar transformers, resulting in smaller overall package sizes, a low 16.51mm maximum profile, and higher power density levels. The unique winding technology also allows the parts to be easily and quickly modified for custom voltage / power applications with no upfront tooling charges to the customer. Featuring a split primary design for efficient 120V or 380V operation, the transformers are optimized for offline and PFC-derived switchmode power supplies and full-bridge / half-bridge converters. Designed to meet MIL-PRF-27 requirements, the devices feature overmolded windings for rugged applications and are environmentally sealed for operation in harsh environments. The series features operating frequencies from 100kHz to 500kHz, power dissipation of 3W, rated current to 22A, leakage inductance down to 1.30µH, and minimal parasitic variation. The devices offer a temperature range of -55C to +130C, with power derating above +105C.