Flat coated copper sheet, flat copper sheet for flat transformers, flat winding.

【Flat coated copper sheet, flat copper sheet for flat transformers, flat winding】

The core advantage of using flat copper sheets as windings for flat transformers is to significantly reduce high-frequency losses, improve current carrying capacity, and make the transformer thinner and better dissipate heat. ‌‌

The main points are as follows:

1) Reduce high-frequency losses: At high frequencies, current will concentrate on the surface of the conductor (skin effect), resulting in low utilization of circular enameled wires. Copper sheet is a flat structure with a large surface area, which can fully utilize the conductor cross-section, effectively suppress eddy current losses caused by skin effect and proximity effect, and lower AC impedance.

2) Support high current output: Copper sheets have a large cross-sectional area and strong current carrying capacity, especially suitable for low-voltage high current scenarios (such as using copper sheets directly for secondary windings, and a single module can withstand hundreds of amperes of current).

3) Reduce leakage inductance: The copper winding and magnetic core are tightly attached, with minimal inter turn gap and good magnetic coupling. The leakage inductance can be as low as 2nH, far superior to traditional wound transformers, which is crucial for the efficiency of high-frequency switching power supplies.

4) Beneficial for heat dissipation: Copper sheet itself is also a good thermal conductor, and coupled with the large heat dissipation area of the planar magnetic core structure, heat can be dissipated faster, allowing for higher power density.

5) Low height and good consistency: Copper sheet stacking makes the transformer very thin overall, suitable for power modules with limited space; The winding structure is repeatable and has high consistency in mass production. ‌‌