1kW Planar Transformer Innovation: Engineered for Next‑Gen Power

Hybrid Winding Architecture for High‑Performance Resonant Converters

Payton Planar Magnetics introduces a new 1 kW planar transformer featuring an advanced hybrid winding system to address the challenges of modern power electronics. This design integrates flat copper stampings on the secondary side (handling 12 V at 85 A) for exceptional low resistance, high current capacity, and precise form factor control.

On the primary side, litz wire replaces conventional PCB windings to effectively suppress skin and proximity effects during high‑frequency operation. This choice significantly raises the self‑resonant frequency, which is essential for resonant topologies like LLC and DAB, resulting in lower losses, improved EMI characteristics, and the ability to sustain higher switching rates.

Optimized Thermal Management for Demanding Environments

The transformer is engineered for conduction cooling via baseplate, with a maximum heatsink temperature of 95°C and an internal hotspot limit of 125°C. Even under intense thermal conditions, it achieves 99% efficiency through carefully selected materials and streamlined heat flow paths.

This thermal capability ensures reliable performance in applications facing space constraints and elevated ambient temperatures, such as data center supplies, EV inverters, aerospace power stages, and compact industrial motor drives.

Technical Specifications and Design Benefits

The unit is rated for 1 kW output at 12 V and 85 A from a 400 V input, making it fully compatible with resonant converter architectures. Its conduction‑cooled design prioritizes efficiency and compactness, delivering the power density required for cutting‑edge systems.

Payton’s engineering team offers full customization support, including 48‑hour design iterations and rapid sample availability. Contact us at [email protected] to explore integration options for your topology.

Core Specifications

• Power rating: 1 kW
• Output: 12 V at 85 A
• Input voltage: 400 V
• Efficiency: 99%
• Cooling method: Baseplate conduction (95°C heatsink, 125°C hotspot max)
• Topology support: Resonant (LLC, DAB, etc.)

>> Read more about Modeling Winding Losses in High‑Voltage Planar Transformers