Transformers in Small, Mini and Micro versions – Production of dedicated components for electronics, automotive and high-frequency converters
The miniaturization of electronics, increasing power density, and the development of modern power electronics systems are driving a dynamic increase in demand for mini and micro transformers. Custom miniature transformers are currently a key component of switching power supplies, isolated DC/DC converters, RF devices, medical electronics, automotive electronics, IoT, telecommunications, embedded systems, and industrial electronics.
Producing custom mini and micro transformers allows for the optimization of energy efficiency, EMI parameters, PCB size, galvanic isolation, operating frequency, operating temperature, and high-frequency parameters!
At NEOTECH, we also have unique experience in the production of ferrite transformers for antenna applications! The photo below shows custom 3D antennas with three windings on a single common core or body!
Production of dedicated miniature precision transformers
Compact miniature transformers and microtransformers are designed for high-frequency switching. They are small in size and, depending on the design, provide high efficiency and high output power.
Applications: galvanic isolation, flyback converters, forward converters, push-pull converters, half-bridge and full-bridge rectifiers, isolated DC/DC converters, LAN transformers, pulse transformers, and RF transformers.
The production of miniature transformers ensures precision in custom applications. Custom mini transformers can be designed according to the requirements of the transformer ratio, power, voltage regulator, operating frequency, regulation parameters, EMI parameters, operating characteristics, leakage inductance, and coupling factor.
At NEOTECH, we can manufacture, upon request and specifically for your project, the following: SMD transformers, THT transformers, ferrite transformers, pulse transformers, high-frequency transformers, micro transformers, and RF transformers.
Manufacturing capabilities of custom miniature transformers
The production of custom transformers includes: electromagnetic design, thermal optimization, winding design, material selection, prototyping, fabrication, measurements, and testing.
Custom pinouts (terminal layouts), winding ratios and layouts, multi-winding designs, ultra-miniature transformers, high-insulation transformers, and custom housing designs are available.
The approximate ranges of electrical and mechanical parameters are presented below:
| PARAMETER | TRANSFORMERS | |
| Wire type | Solderable and non-solderable: CuL 155 – 200, Gr.1 – 2 (typically) Selfbonding: FSP 18, STP 18, PSP 15 and etc. | |
| CuAg silver-plated wires for HF applications | ||
| Other types of wires are available on request. | ||
| Wire diameter | Min | 0.04 mm |
| Max | 2.10 mm | |
| Other wire diameters are available on request. | ||
| Winding direction | Left, Right | |
| Number of winding layers | Min | 1 |
| Max | TBD | |
Coil shape | Depends on the shape of the ferrite core. Cylindrical, spool, bar, and others. | |
| Possibility of placing a UV glue point for automatic assembly (Pick & Place machines). | ||
| Unusual, non-typical shapes or requirements – Possibility of individual arrangement upon request. | ||
Types of cores used | Ferrite Cores, Powder Cores, Metal Composite | |
| Typical saturation current ranges (Isat) |
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| Typical DC resistance (DCR) |
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| Typical operating frequency | Depends on the application and the choice of materials (especially the hysteresis of the ferrite core)
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| Leads | Typically – soldered to the core. | |
| Thermocompression welded. | ||
| Metalized with silver wire for reinforcement. | ||
| Other versions are available upon request. | ||
| Location and shape of pins | Typically – wrapping around specific core points. | |
| Depending on the core shape – pinout according to the core and customer requirements. | ||
Soldering | Pb Free | |
| Pb (on request) | ||
Contact
If you have any questions, need more information, or would like to place an order, please contact us.
