If you request a PCB with an integrated planar transformer or a stand-alone planar transformer, a development process begins for us that differs significantly from standard PCBs. The requirements are not only electrically demanding, but also pose special challenges in terms of design, material selection and production. Our aim is to support you in achieving efficient, reliable and series-ready solutions.
Specification and coordination
It all starts with the Clarification of your requirements:
- What voltages and currents must be transmitted?
- What insulation distances and construction heights are required?
- Which standards must be complied with for safety-relevant applications?
Particularly in the case of high safety requirements, we advise you at an early stage on how clearance specifications can be reliably implemented in the PCB layout. Only if electrical, mechanical and manufacturing requirements are considered together from the outset can subsequent correction loops be avoided.
PCB stackup and material selection
Planar transformers usually require a multi-layer circuit board with defined copper thicknesses.
- Multilayeredness: Depending on the performance class, 4 to 8 layers may be necessary - often even more, with a number of layers in the high double-digit range being required from time to time.
- Copper thickness: Standard PCBs often use 1 oz copper; for planar transformers we also use up to 4 oz or connect several layers in parallel to ensure current carrying capacity and efficiency.
- Thermal management: High-performance planar transformers generate heat. We support you in the selection of suitable materials and cooling structures to ensure that your PCB dissipates heat optimally and prevents overheating.
- Mechanical precision: Precise cut-outs for the ferrite core ensure that the transformer can be mounted precisely later on.
We recommend materials and stackups that optimally support your requirements in terms of efficiency, performance and functionality.
Cost optimization
We can also advise you on cost-efficient manufacturing processes, to minimize material and production costs without compromising the quality of the PCBs. Efficient designs, optimum panel design, the best possible layer structures and therefore cost-effective production processes help to implement your projects economically.
Cooperation and coordination
Successful implementation can only be achieved through Closely coordinated cooperationWe advise you on layer structure, copper thickness, winding strategy and insulation as early as the design phase. Regular replacement reduces correction loops, increases production reliability and ensures that your PCB can be manufactured later without any problems.
Manufacturing challenges
The production of a printed circuit board with a planar transformer requires special attention:
- Copper thickness and structure width: Thick copper layers are more complex to etch. Precision is crucial, as even small deviations can change the magnetic characteristics.
- Isolation: Strict distances must be maintained between the primary and secondary sides. Special insulation layers or milled slots are used here.
- Drill holes and vias: Several current vias connected in parallel and/or filled microvias ensure that high currents are safely conducted - this requires particularly clean production processes.
- winding strategy: Spiral or meander shapes, interleaving and the arrangement of the connecting vias influence efficiency, leakage inductance and
EMC behavior. - Testing: Electrical testing of the coil requires special equipment and in-depth expertise in order to reliably ensure quality.
Conclusion
The production of a PCB with an integrated planar transformer is significantly more demanding than the production of a standard PCB. For you as a customer, this means
- Detailed coordination and continuous advice
- Maximum precision in all production steps
- Optimum insulation, copper thickness, winding strategy and heat dissipation
This results in printed circuit boards that not only conduct signals, but also Actively convert energy - reliable, efficient and ready for series production. They form a central component for modern, high-performance electronic solutions.
Questions?
Do you have questions about planar transformers or need support with the layout and development process?
Please feel free to contact the experienced experts at our Technical Support department.
