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What Is Transformer PCB, Its Uses, Working, And Types?

Transformers consider the essential part of a PCB. But each PCB requires

a different type of transformer based on their needs and usage. This

article focuses on the features of PCB-mounted transformers, which help

you identify the best transformer.

Transformers come in compact and lighter forms and can work under

heavy loads. Moreover, one must consider a few important factors before

considering any transformer for the device. Therefore, let’s dive into the

details of transformers, their types, features, and function.

Table of Contents

Overview Of Transformer PCB

Generally, a transformer consists of two coils that are physically separated

from each other. These coils are coupled with the electromagnetic field

inductively, which occurs between the secondary coil and primary coil. A

Printed Circuit Board-Mount transformer acts as a basic component that

incorporates the surface of the PCB. This helps in

transferring power between two circuits. Another thing to understand

here is that the process of transferring power occurs through coils while

keeping them completely isolated.

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It has an input and an output side. The transformer keeps both sides

separated. Separation serves as an essential need in this process.

An actual transformer does not use a simple type of structure in which the

square magnetic central part is surrounded with coils and gives magnetic

coupling. However, it follows the complex design of the core and coil. This

involves core-shell, stacked topologies, and lamination. A designer must

take specific considerations while designing the board. Make sure to keep

the coils separate and focus on the strength of inductive coupling, as this

determines the power transmission efficiency.

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What Are Transformer PCBs?

Transformer

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Transformer acts as an electrical component that helps transform

electrical power from one part of the circuit to another circuit part.

Transformer offers more benefits and features to the devices. A

transformer helps in isolating the device from a power source and

disconnecting its connection from the earth. This ultimately protects

anyone from touching the open wires accidentally. Moreover, it also helps

in converting the current and voltage without impacting the power level.

The incorporation of transformers in the power source can help to do so.

It also amplifies the wave input. Additionally, it aids in converting the

electricity of wires to an appropriate current and voltage for each device.

Transformers that mount over the surface of circuit boards refer as

PCB-mount transformers. They act as vital electrical components. As the

majority of PCBs operate on less consumption of power, the addition of

transformers helps the PCB to amplify those signals and enhances the

electricity power.

How Do Transformer PCBs Work?

Along with the fact that transformers help in transferring electrical power

between two circuits. Let’s dive further into details. How can a transformer

do that? Generally, a transformer consists of three basic parts, which

include both magnetic as well as electronic components. However, these

parts include the primary coil, core or central part, and secondary coil.

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However, as far as its functionality concerns. Transformers follow three

basic steps to work. Firstly, the current passes through the primary coil.

Here it induces the flow of a magnetic field inside the metallic core. It then

passes through the secondary coil. Here, the magnetic field flow induces

the flow of electricity in the second coil.

Composition of Transformer PCBs

Each PCB transformer consists of two types of coils. Primary and

secondary. These coils are made of copper wire which is tightly coiled

around the core of the magnetic field. Magnetic core also consists of metal

alloys like steel or other material. Moreover, transformers also contain

outer casings and terminals.

However, PCBs follow two different types of mounting techniques to

incorporate the transformer over the board surface. These two methods

include:

· Surface Mounted

This method uses solder paste and soldering techniques to solder the

transformer over the PCB surface directly. However, if the PCB is exposed

to harsh environments or greater heat, it may loosen the solder paste.

· Through Hole

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This approach needs to drill holes and use leads to pass through those

holes. This helps in soldering the transformer using through-holes on each

side of the PCB.

Specifications of Transformer PCBs

PCB transformers also have some specifications to look into. These factors

include:

· Primary And Secondary Ratings

This rating depicts the rate of current and voltage between the primary

coil and the secondary coil. Firstly, check the value of the output voltage.

Then look into the current value and compare it with the design value.

Moreover, ensure that the density of power increases as this dissipates

the heat from the faulty PCB.

· Power Rating And Efficiency

The power rating indicates the type of current, DC or AC. It also

determines the transformer limit for handling power. You must consider

the voltage frequency too. Moreover, power efficiency determines the

efficiency of DC under little load.

· Form Factor

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A transformer can either incorporate vertically or flat over the surface of

the board. However vertical transformers may save some space on the

board, but they are susceptible to vibrations.

· Mounting Style

Ensure the type of transformer. The SMT-type transformers need

soldering techniques to incorporate them over the board.

Whereas, THT type transformers need drilling holes and lead to pass

through the holes and then solder the transformer over the other side of

the PCB. These THT transformers provide greater heat resistance.

· Cooling Mechanism

PCB-mount transformers consume less power. Thus, this creates less heat

which automatically obscures the need for any external cooling system. At

the same time, the planar PCB transformers can easily hole a

heat-dissipating sink over the device.

· Inductance

Inductance generally describes the efficiency of how well a transformer

creates a connection between both circuits. However, inductance also

belongs to the DC-DC converter PCBs where the power efficiency

determines the performance of coupling of a transformer simplicity.

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Types Of Transformer PCBs

The PCB transformer comes in various shapes and sizes with different

power converters.

· Audio transformers

This transformer helps in converting the signal and sounds from a higher

frequency level of 300 Hz to a lower frequency level 20kHz.

· Auto Transformer

Autotransformers contain one winding coil. This solely acts as primary as

well as secondary. This enables them to have different types of secondary

voltage configurations. One can connect the taps over the transformer

using distinct conversion ratios. As it has no separate coils, they do not

give isolation

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· Balun Transformers

This allows the interface of unbalanced and blanched lines without

affecting the arrangement of impedance on either side.

· Current Sense Transformers

These transformers identify and analyze the ampere in a primary coil.

Then creates a proportional current in a secondary coil.

· Flyback Transformers

This transformer is also referred to as LOPT or FBT. It generates high

voltage signals of saw-toothed at a very high rate of voltage.

· Interface Transformers

These transformers help in communication and telecom circuits to isolate

signals.

· Lighting Transformers

These transformers help in generating appropriate power for lumination

and lighting systems.

· Medical Transformers

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These transformers follow strict rules and regulations for safety. This

enables them to be used safely in medical, surgical, and operating devices.

· Power Transformers

These types of transformers help in enhancing the power of the power

supply in the device. Manufacturers use these transformers in speakers

and amplifiers to amplify the singles and sound.

· RF Transformers

These transformers help in matching impedance, provide isolation of

Direct current between the circuits, and provide step-ups and step-downs

of voltage and current.

· Resonant Transformers

These types of circuits are used in radios which aid in switching the power

supply and bandpass filters.

· Switch Mode Transformers

These transformers function under a low supply of voltage. Thus making

them ideal to use in domestic and industrial applications.

Should You Design Your Own Transformer PCBs Or Inductor?

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Generally, many designers want to build their own power conversion

electrical components. This, however, does not seem impossible to do.

Anyone can do so. But it requires complex knowledge. Because of the

safety and regulatory measurements on magnetic power, one must look

for a PCB transformer manufacturer and design components with them.

The best way is to select the best off-the-shelf transformer that suits your

needs. Then utilize a regulator over the output value; this gives you the

required output voltage.

However, even if you work with a PCB transformer manufacturer, you

have to specify a few things first. For example, its material, type of process,

and the circuit board. Each manufacturer has their own way of methods

that they follow to produce transformers without hurting the safety

measures. These measures ensure that you get a perfect, error-free, and

safe design without damaging anything.

Conclusion

This article briefly describes the PCB transformers, their types, function,

how they work, and factors to consider while choosing them. This also

explains the electromagnetic mechanism of transformers. Moreover, the

factors help you understand which transformer acts best for your device.

It also explains how each type differs from each other. This article gives

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basic yet important details about PCB transformers, how, where, and

when to use them.

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