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High Power ER50 Planar Transformer 3KW 5KW DC-DC Converter Transformer for EV Charger and Data Center Power Supply
Product Introduction
The ER50 Series High-Power Planar Transformer represents the next generation of magnetic component technology, specifically engineered for high-wattage power conversion systems ranging from 1kW to over 5kW. By replacing traditional bulky wire-wound coils with a low-profile, multi-layer PCB or copper plate winding structure, the ER50 is optimized for advanced power electronics where efficiency, minimal vertical space, and extreme power density are non-negotiable requirements.
Parameter
Typical Value / Spec
Core Type
ER50 (Planar Ferrite Core)
Winding Structure
Multi-layer PCB / Flat Copper Busbar
Mounting Type
Direct PCB Mount / Chassis Mount
Dimensions
Approx. 50.0mm x 50.0mm x 18.0mm (Customizable)
Power Capability
1.0kW - 5.0kW+ (High Power Density)
Operating Frequency
100KHz - 500KHz
Efficiency
99.2% - 99.6% (Typical)
Hi-Pot (Isolation)
2.5KV - 4.0KV AC / 1min
Leakage Inductance
< 0.5% - 1% (Ultra-low)
Inter-winding Capacitance
Low (Optimized for High Frequency)
Core Material
PC44 / PC95 / PC97 Mn-Zn Ferrite
Ae (Effective Area)
238.0 mm²
Ve (Effective Volume)
16400 mm³
Insulation Class
Class F (155°C) / Class H (180°C)
Operating Temp
-40°C to +125°C (Incl. Temp Rise)
Compliance
RoHS, REACH, IATF16949 (Automotive Ready)
Cooling Requirement
Forced Air / Cold Plate / Heat Sink
Product Features
High-Capacity ER50 Geometry: Utilizes the ER50 ferrite core, which offers a massive effective cross-sectional area (Ae≈238 mm²), allowing for high magnetic flux handling with a significantly reduced risk of saturation under high-current loads.
Advanced Winding Technology: Features integrated multi-layer PCB windings or heavy-gauge flat copper busbars, ensuring precise turn ratios and minimized skin effect at high frequencies.
High-Frequency Optimization: Designed to perform flawlessly in high-frequency switching environments, typically between 100kHz and 500kHz, supporting modern SiC (Silicon Carbide) and GaN (Gallium Nitride) topologies.
Low-Profile Design: Maintains a remarkably low vertical height (typically under 20mm), enabling the design of ultra-slim power modules and highly integrated enclosures.
Exceptional Insulation: Provides superior dielectric strength and high isolation voltage (up to 4kV or higher) through reinforced insulation systems and specialized potting materials.
Product Applications
Electric Vehicles (EV): A core component for high-power On-Board Chargers (OBC) and bidirectional DC-DC converters in hybrid and fully electric vehicles.
Renewable Energy: Used in high-power Solar Inverters and energy storage systems (ESS) for efficient grid-tie energy conversion.
Data Centers: Powers high-performance Server Power Supplies (PSU) and blade server racks requiring 99%+ efficiency.
Industrial Equipment: Ideal for high-frequency welding machines, large-scale industrial lasers, and Uninterruptible Power Supplies (UPS) for mission-critical infrastructure.
Product Advantages
Unmatched Power Density: Delivers several times the power handling of traditional wire-wound transformers of similar volume, allowing for a drastic reduction in the overall size of the power supply.
Superior Thermal Management: The flat, large-surface-area structure provides a massive cooling interface, facilitating rapid heat dissipation via heatsinks or liquid-cooled cold plates, ensuring stable operation at full load.
Minimal Parasitic Parameters: The tight interleaving of PCB layers results in ultra-low leakage inductance and reduced parasitic capacitance, which drastically lowers switching losses and EMI noise.
Unrivaled Consistency: Unlike manual wire winding, the automated PCB manufacturing process ensures that electrical parameters are identical across every unit, guaranteeing perfect repeatability in mass production.
Reduced AC Losses: The flat conductor geometry significantly mitigates the proximity and skin effects, leading to much lower AC copper losses compared to traditional round-wire transformers at high frequencies.
Company Strengths
Chipsen Electronics Technology Co., Ltd., established in 2000, is a specialized manufacturer of high frequency transformer, low frequency transformer, toroidal inductor, SMD power inductor, super high current inductor, choke coil and switch. Chipsen has got a good reputation in domestic and oversea markets which include North & South America, Europe and Southeast Asia.
Chipsen possesses a professional management team, as an ISO9001, IS014001 & IATF16949 audited company, which always commits to producing environmental protection and qualified products. Our products are certified by UL Class B/Class F/Class H, CQC and RoHS, and obtained 21 patents. These achievements mainly come from our strong R&D team, providing various solutions for temperature decreasing, noise cancellation and coupled radiation conductivity. Our products widely used in various fields of new energy, PV, UPS, Robotics, smart home, security systems, health care and communication.
Vision: To Be Global Transformer Brand Supplier
Mission: Create Values for Customers and Society, Grow with Customers and Staffs
Q1: How does the ER50 Planar Transformer manage thermal dissipation at continuous power levels exceeding 5kW, and what cooling strategies are recommended?
A: The ER50 Planar Transformer is engineered with a high Surface-Area-to-Volume ratio, which is significantly superior to traditional wire-wound transformers. The flat geometry provides a massive, direct thermal interface between the ferrite core and the mounting surface.
Thermal Path: Because the PCB windings are in close contact with the core, the heat generated by copper losses is rapidly conducted to the core surface.
Cooling Strategies: For 5kW+ applications, we recommend mounting the flat base of the ER50 directly onto a Cold Plate (liquid cooling) or a High-Performance Heatsink with high-conductivity thermal interface material (TIM). This setup achieves a very low thermal resistance (Rth), preventing thermal runaway and allowing the transformer to operate at high current densities that would cause traditional round-wire transformers to overheat.
Q2: Why is the ER50 Planar design preferred over traditional wire-wound ER50 cores for high-frequency Silicon Carbide (SiC) or Gallium Nitride (GaN) power stages?
A: Modern SiC and GaN power stages operate at extremely high switching frequencies (200kHz-500kHz+) and fast dv/dt rates, which demand ultra-low parasitic parameters. The ER50 Planar Transformer offers three critical technical advantages in this environment:
Ultra-Low Leakage Inductance (Lk): By using precise Interleaved PCB Winding (where primary and secondary layers are interleaved), we can achieve Lk values below 0.5% of the primary inductance. This minimizes voltage ringing and spikes across the SiC/GaN FETs, reducing the need for heavy snubber circuits and increasing overall system efficiency.
Minimized Skin and Proximity Effects: Traditional round wire suffers from severe AC losses at high frequencies. The flat, thin copper foil or PCB traces in the ER50 planar design significantly reduce the Skin Effect, ensuring that the entire conductor cross-section is utilized for current flow.
High Repeatability: Since the windings are etched on a PCB rather than manually wound, the Inter-winding Capacitance (Cp) and Lk remain identical across every production unit. This ensures that the tuned dead-time and EMI filter performance are consistent for every power supply built.
Company Details
Bronze Gleitlager
,
Bronze Sleeve Bushings
and
Graphite Plugged Bushings
from Quality China Factory
Business Type:
Manufacturer
Year Established:
2007
Total Annual:
28820000-29820000
Employee Number:
400~450
Ecer Certification：
Verified Supplier
Chipsen Electronics - Supplier to Fortune Global 500 Companies
Magnetic Components Engineered for Performance & Reliability
Founded in 2007, Dongguan Chipsen Electronics Technology Co., Ltd. is a professional manufacturer specializing in magnetic components and micro switches.
...
Chipsen Electronics - Supplier to Fortune Global 500 Companies
Magnetic Components Engineered for Performance & Reliability
Founded in 2007, Dongguan Chipsen Electronics Technology Co., Ltd. is a professional manufacturer specializing in magnetic components and micro switches.
...
