Magnetics Business & Technology - March/April 2021 - 20

PRODUCT NEWS

Pulse Electronics Rolls Out New Power Magnetic Components with Advanced Designs and
Winding Technology

Pulse Electronics continues to innovate and bring to market advancements in power magnetic products including new transformers that have twice the power density of their forbears and a series
of chokes that use the automated round wire coil forming technology developed originally for its high current inductor product line.
Leveraging the research presented in the company's 2019 APEC
presentation, " Power Transformer Core Optimization Enables
Dramatically Increased Power Density " , Pulse has released an
improved DC/DC transformer series that maintains the industry
standard footprint but doubles the component power density to over
11W/cm3. Its new EP7+ series and EP10+ series, depicted above,
achieve the performance enhancement by using three-dimensional
finite element analysis to balance the flux utilization in the core,
thereby minimizing AC losses and increasing saturation currents.
The series is comprised of twenty-four parts designed for continuous mode flybacks and active clamp forwards ranging in output
power from 17W to 35W.
" Pulse is able to use our sophisticated design skills, knowledge of
proximity loss minimization and understanding of our customers
technical roadmaps to anticipate the market needs and continually
improve magnetic component performance, " said John Gallagher,
product marketing for Power PBU at Pulse. Although primarily
designed for PoE and PoE+ applications, including IP phones,
security cameras, instrumentation and automation test equipment,
they are also suitable for most low voltage switch-mode power supply designs.
In another recent development, Pulse
expanded its range of surface mount current
sense transformers with the introduction of
its first safety standard compliant products
with high isolation and enhanced insulation.
They use the company's patented sidecar
construction, developed for its high isolation
transformer series, where the primary winding is molded into the plastic base forming
a solid insulation barrier and allowing a
compact size.

Pulse transformers
with sidecar construction

The high isolation transformer series was
launched in 2015 as a compact surface
mount package that could achieve a high level of creepage without requiring encapsulation, making them less expensive than
encapsulated transformers. The coil is inserted at one side of the
open package and the high isolation pins placed on the other side.
This configuration separates the coil and pins so there is a greater
creepage distance between them, also enabling the package to be
smaller while still maintaining an optimal creepage distance, ac-

Magnetics Business & Technology * March/April 2021

cording to Gerard Healy, product manager.
" Our existing product line for surface mount current sense transformers, including the ever popular PA1005 EE5 series, remain the
component of choice for applications that require just functional
insulation. However, many emerging applications require at least
basic insulation, particularly where current needs to be measured
across different ground planes. This is a typical requirement for EV
applications with high voltage battery packs. The AEC-Q200 qualification of both platforms make these automotive ready solutions, "
said Healy about the new products.

New Common Mode Choke Series
Also, Pulse expanded its range of surface mount common mode
chokes with the introduction of the PA5140/41 series that use the
fully automated round wire coil-forming technology developed for
its high current inductors. The new series offer the highest available
current in a surface mount package, says the company.
Two platforms offer inductances from 110uH to 470uH with currents
up to 32A. The cores have been designed around the coil dimension to minimize the component size, offering a higher-density
inductance per current solution. The high permeability ferrite material minimizes the number of turns and, thus, the DC resistance,
resulting in their high current rating.
" Traditionally, our customers have selected our popular toroidal
inductors solutions to deliver a surface mount filtering solution.
However, these platforms are less space efficient and the current
capability is limited by the older technology termination style, " said
Healy.
The new self-leaded round wire coil technology allows for larger
wire and higher current carrying capability in a more compact
construction. The new products allow for a 60% reduction in board
spec for the same inductance and current capability while the fully
automated winding reduces cost. The resultant impedance is ideal
for the EMI filtering requirements of modern applications making
them well suited for any high-performance application in the data
communications, computing, industrial and aerospace markets.

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Magnetics Business & Technology - March/April 2021

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