Next‑Gen AI Power Transformer for High‑Frequency, High‑Current Applications

Hybrid Litz and Copper Design for 200 kHz Performance

Developed by Payton Planar Magnetics, this 1000 W full‑bridge resonant transformer is engineered for demanding AI and advanced computing power stages. By combining litz wire on the primary side with stamped copper on the secondary, the design achieves high efficiency and accurate current handling at high frequency, while supporting compact, power‑dense layouts.

The transformer is tailored for high‑current, low‑voltage output stages that must operate reliably under elevated thermal and electrical stress. Its hybrid construction is optimized to reduce losses, manage skin and proximity effects, and maintain stable performance at 200 kHz.

Electrical and Thermal Performance Highlights

This transformer is specified for a 12 V output at 83 A from a 400 V input, delivering 1000 W of power in a compact footprint. It is designed for operation at a switching frequency of 200 kHz, with total power loss limited to just 8 W, supporting high overall system efficiency.

The operating temperature range extends from –55°C to +155°C, with a 95°C heatsink reference, making it suitable for thermally challenging environments. Despite the wide operating range and high current levels, the unit maintains stable electrical characteristics and supports long‑term, reliable operation.

Key Specs

• Output: 12 V at 83 A
• Input: 400 V
• Switching frequency: 200 kHz
• Operating temperature range: –55°C to +155°C (95°C heatsink)
• Power loss: 8 W
• Dimensions: 47 mm × 45 mm × 20 mm

Magnetic Characteristics and Construction

The primary winding uses litz wire to minimize AC resistance and reduce losses at high frequency, while the secondary is implemented with copper stamping for precise geometry and efficient current distribution. This hybrid approach supports both high‑frequency performance and robust mechanical integrity.

Magnetic parameters are carefully tuned for resonant operation. The design features a leakage inductance of 2 µH and a primary inductance of 1800 µH, with an interwinding capacitance of 400 pF, enabling controlled behavior in full‑bridge resonant topologies.

Magnetic Characteristics

• Primary winding: Litz wire
• Secondary winding: Copper stamping
• Leakage inductance: 2 µH
• Primary inductance: 1800 µH
• Interwinding capacitance: 400 pF

Built for AI, Computing, and Power‑Dense Modules

This transformer is targeted at applications where power density, efficiency, and thermal robustness are critical, such as AI accelerators, high‑end computing platforms, and compact power modules. Its small form factor and low loss profile make it well suited for systems with tight space and cooling constraints.

Leveraging decades of experience in custom planar magnetics, Payton delivers a transformer that consolidates high‑frequency performance, high current capability, and reliability in a single, integrated solution. The result is a precision‑engineered magnetic component ready for next‑generation, high‑performance power architectures.