Design on SMPS Transformer

(Topology and Material Selection)

Typical locations where cores are used
 Core Material
• Purpose of the core is:
– To reduce the magnetizing current. (For topologies
such as Forward, Bridge etc we need the magnetizing
current to be as small as possible. For fly-back
topology, though the magnetizing current is used to
transfer energy, the size of the transformer will be
very large to get the required inductance if a core is
not used.)
– To improve the linkage of the flux within windings if
the windings are separated spatially.
– to contain the magnetic flux within a given volume
– In magnetic amplifier applications a saturable core is
used as a switch.
 Core Material
• Different types of material used for cores
– Iron
– Silicon Steel
– Nickel-Iron
– Iron-Cobalt
– Ferrite
– Molybdenum
– Met-glas
 Core Material
• Salient characteristics of a core material
are
– Permeability
– Saturation flux density
– Coercive force
– Remnant flux
– losses due to
• Hysteresis
• Eddy Current
B-H loop of a magnetic material
B-H Minor loops
 Core Material
• The power loss is a function of frequency and
the ac flux swing and is given by the equation

• P = K1 * (frequency)K2 * (Flux Density)K3

• Typical power loss for different material are

given below:
 Material Type Loss
(mw/cm^3)
Phillips, Ferrite 3C90, µ = 110
2300
Phillips, Ferrite 3C81 220
µ = 2700
Phillips, Ferrite 3F3 120
µ = 2000
10 @ 200 G,500 KHz
Phillips, Ferrite 3F4
180 @ 1000G,100KHz
µ = 900 1600 @1000G,500KHz

Frequency = 100 KHz ; B = 1000 Gauss.

 Material Type Loss (mw/cm^3)

EPCOS, Ferrite N27, µ = 2000 231.5

EPCOS, Ferrite N67, µ = 2100 68.57
EPCOS, Ferrite N87, µ = 2200 50.7
Met-glas, 2714 AS 105
Met-glas , Powerlite, C core 840
Met-glas , Micolite µ = 245 560
Met-glas , Micolite µ = 270 630

Frequency = 100 KHz ; B = 1000 Gauss.

 Material Type Loss
(mw/cm^3)
Moly Powder Permalloy µ = 12 870
Moly Powder Permalloy µ = 60 360
Moly Powder Permalloy µ = 200 1440
Magnetics , Material K µ = 1500 110
Magnetics , Material R µ = 2300 70
Magnetics , Material P µ = 2500 125
Magnetics , Material F µ = 3000 225
Magnetics , Material H , µ = 15000 2200

Frequency = 100 KHz ; B = 1000 Gauss.

 Material Type Loss
(mw/cm^3)
Magnetics Tape wound 870
Supermalloy
Magnetics Tape wound 360
Square-Permalloy
Magnetics , Material P µ = 2500 125
Magnetics , Material F µ = 3000 225
Magnetics , Material H , µ = 15000 2200

Frequency = 100 KHz ; B = 1000 Gauss.

Performance factor