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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 steadily increasing, creating a seller's market for upstream raw materials. As downstream users, power supply manufacturers have the ability to source globally, forming a buyer’s market. However, within the mature electronic transformer industry, the only viable path forward is through technological innovation. While innovation can be challenging in such a saturated field, even small improvements in individual components can lead to new ideas and breakthrough products.
To pursue technological advancement, it's essential to keep the end goal in mind. Electronic transformers, like any product, must perform specific functions under defined conditions. The key objective is achieving optimal performance at the best possible price. Modern power supply products are trending toward being lighter, thinner, shorter, and smaller, pushing the industry toward miniaturization and portability. This means electronic transformers must adapt to the size and weight constraints of the final product. At the same time, rising material costs—especially for core and conductive materials—have made reducing both volume and cost a central focus for development.
Silicon steel is a commonly used core material in industrial frequency power supplies. To minimize the amount of iron used, the working flux density of silicon steel must be increased. This is determined by both its saturation flux density and loss characteristics. Since efficiency is a critical factor in electronic transformers, many power supplies now include standby loss requirements to improve energy efficiency. Core loss is a major contributor to this standby loss, so there are strict demands on the efficiency or loss levels of these transformers.
Over the past year, the prices of oriented and non-oriented cold-rolled silicon steels have risen significantly. Compared to R-type, CD-type, and EI-type cores, wound toroidal cores can reduce core material costs by over 20% due to lower material consumption. This not only saves costs but also expands the application scope of electronic transformers. Wound toroidal cores make full use of the properties of oriented cold-rolled silicon steel, allowing for a much higher working magnetic flux density than non-oriented types. Additionally, unlike traditional cores, they minimize waste, achieving a material utilization rate of over 98%.
For large power transformers, high-density core materials can reduce the number of coil turns without compromising core size or volume. In a scenario where copper prices are significantly higher than those of core materials, this design approach offers a more cost-effective solution.
Soft ferrite is widely used in high-frequency power supplies as a core material. Compared to metal soft magnetic materials, soft ferrite has several limitations, including low saturation magnetization, low magnetic permeability, and a relatively low Curie temperature. As temperature increases, the saturation magnetization (Bs) and unit volume power loss (Pcv) of soft ferrite change, with Bs decreasing and Pcv first dropping before rising 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, lowers copper usage, and cuts costs. High-temperature, high-saturation, magnetically encapsulated ferrite materials can extend the operational temperature range of electronic transformers to 120°C or even 150°C.