Resonant
LLC half bridge, LLC full bridge, CLLC, and SRC. Magnetizing and leakage inductance are design targets here, not by-products, because your resonant tank depends on both.
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Custom High Frequency Transformers
ConverNova designs and manufactures custom transformers for power electronics, from 50 Hz line frequency up to 2 MHz. Based in Madrid, Spain, we return an engineering answer usually within 24 hours, deliver prototypes in 4 to 8 weeks, and manufacture from a single unit to production series with no minimum order quantity. Cores include ferrite, nanocrystalline, amorphous and powder; windings include litz from 0.03 mm strands, triple insulated wire, copper foil and planar.
Topologies
Built around your converter, not around a catalog part.
Tell us the topology and the waveform and the design starts there. These are the ones we are asked for most often, and the ones the specification form lists.
Bridge
Phase shift full bridge with centre tap or full wave rectifier, and dual active bridge. Interleaving and winding order chosen for the leakage your control loop expects.
Single switch and line
Flyback and forward, plus gate drive, current sense and 50 or 60 Hz isolation transformers when the application asks for them.
Specification range
What we can build.
If what you need sits outside this table, ask anyway. The answer is usually yes, and when it is no we say so.
Send us your spec- Frequency
- 50 and 60 Hz line, through to 2 MHz for SiC and GaN switching stages
- Power
- From a few watts to hundreds of kilowatts, single or multiple outputs
- Cores
- Ferrite (Ferroxcube, TDK), nanocrystalline (VAC, Hitachi), amorphous, powder (Magnetics, Micrometals). Custom machined geometries and production tooling available
- Windings
- Litz from 0.03 mm strands, triple insulated wire, copper foil, edge wound flat wire, planar on your PCB or on ours
- Construction
- Bobbin or bobbinless, tape wound, vacuum impregnated, varnished, potted in resin or in an aluminum housing
- Isolation
- Reinforced and functional isolation, creepage and clearance to the standard your application is qualified against
- Temperature
- Minus 55 to plus 125 degrees C depending on materials and insulation class
- Test
- Inductance, leakage, interwinding capacitance, DC resistance, hipot, partial discharge, temperature rise under your real waveform
What arrives
A design proposal, not a price list.
Usually within 24 hours of your specification, and before you have spent anything, the first proposal carries the numbers you need to judge the design.
Loss distribution
Estimated core losses and winding losses, split, at your waveform and your switching frequency. Not a single efficiency figure with no working shown.
The inductances
Magnetizing inductance and leakage inductance, with the interleaving and winding order that produce them.
Thermal and mechanical
Expected hotspot temperature for your cooling method, and the dimensions, so you know it fits your keepout before anything is wound.
Straight answers
Custom transformers, the usual questions.
What is the lead time for a custom transformer prototype?
Four to eight weeks from an agreed design, when the required raw materials are
in stock. The engineering answer, with a first design proposal, is one we aim to send inside 24 hours.
What is the minimum order quantity?
There is none. Prototypes, samples and production come off the same drawing, so
nothing gets redesigned when the volume arrives.
What frequency range do you cover?
From 50 and 60 Hz line frequency up to 2 MHz, designed for modern SiC and GaN
switching semiconductors.
Which core materials do you work with?
Ferrite from Ferroxcube and TDK; nanocrystalline from VAC and
Hitachi; amorphous alloys; and powder from Magnetics and Micrometals. When no standard geometry fits,
we machine a custom core.
Can you hit a leakage inductance target?
Yes. And we will tell you honestly when the target fights the isolation you also
asked for. Interleaving, winding order and the bobbin all move it. We measure it and put the
number on the report.
Do you build to print, or do you design it?
Whichever your project needs. If you already have a working design, send us the
drawing and we produce it. If you do not, we design the optimal transformer for you: optimal
in efficiency, in performance and in cost.
Construction
Transformer construction.
Foil, litz and taped windings, on stacked or gapped cores, terminated to leads or to pins.
Start here
Send us your transformer spec.
Topology, frequency, voltages, currents, isolation and the space you have. Or just the schematic and the waveform. Engineering answer, we aim for 24 hours.