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Electronic transformer technology innovation in power supply is the way out
In recent years, the cost of core and conductive materials used in electronic transformers within power supplies has been on a steady upward trend. This has led to a seller's market for upstream raw materials. As a downstream user of electronic transformers, companies have the ability to source globally, creating a buyer’s market. However, the middle layer of the electronic transformer industry faces a tough challenge—only through technological innovation can they break free from this dilemma. In an already mature industry, innovation is not easy, but even small improvements in key areas can lead to fresh ideas and innovative products.
Pursuing technological advancement requires a clear focus on the ultimate goal. Electronic transformers, like any product, must fulfill specific functions under defined usage conditions. The primary aim is to achieve the best performance at the lowest cost. Today’s power supply products are trending toward being lighter, thinner, shorter, and smaller, moving toward miniaturization and portability. Therefore, electronic transformers must adapt to these size and weight constraints. At the same time, rising material costs have made it more important than ever to reduce both volume and cost. These factors have become the main direction for the development of modern electronic transformers.
Silicon steel is a commonly used core material in industrial frequency power supply transformers. To minimize the amount of iron used, the working flux density of silicon steel must be increased. However, this is limited by the saturation flux density and core loss. Since efficiency is a crucial factor in electronic transformers, many power supplies now impose strict standby loss requirements to save energy. Core loss is the main contributor to standby loss, so there is a growing demand for higher efficiency and lower losses in transformers.
Since last year, the prices of both oriented and non-oriented cold-rolled silicon steels have increased significantly. Compared to R-type, CD-type, and EI-type cores, wound toroidal cores offer over 20% savings in core material costs. They also allow for a broader application range due to reduced material consumption. Wound toroidal cores fully utilize the properties of oriented cold-rolled silicon steel, achieving a much higher working magnetic flux density than non-oriented versions. Moreover, unlike traditional cores, they generate almost no scrap, with a material utilization rate exceeding 98%.
For large power transformers, high-density magnetic cores can reduce the number of coil turns without increasing the core size or volume. Given that copper is currently far more expensive than core materials, this design approach offers a more cost-effective solution.
Soft ferrite is widely used in high-frequency power supplies. Compared to metal soft magnetic materials, it has several disadvantages, such as low saturation magnetization, low permeability, and a low Curie temperature. As temperature increases, its saturation magnetization (Bs) and unit volume power loss (Pcv) change. Bs decreases, while Pcv first drops and then rises after reaching a minimum point. Therefore, under high-temperature conditions, maintaining a high Bs allows for a higher working magnetic density (Bm), which reduces the number of coil turns and lowers copper usage and overall costs. High-temperature, high-saturation, magnetically encapsulated ferrite materials can even extend the operating temperature limit of electronic transformers up to 120°C or even 150°C.