Bobbin Wound Transformers

A Bobbin Wound Transformer is a transformer that is designed with the coil wound on a coil form or bobbin. The core structure is then mounted to the bobbin. Bobbin wound transformers can be designed to operate from 60Hz, or line frequency, well into the MHz range. Where are Bobbin Wound Transformers found? Switch mode power supplies Power conversion applications Circuit isolation applications Filter circuits Any application that the transformer can be designed on a bobbin or coil form Design upper limits of a Power Transformer:

Typical minimum requirements to be specified for a Bobbin Wound Transformer are: Power rating in VA. Operating frequency in Hz. Number of primary windings. Number of secondary windings. Operating voltages levels. Operating current levels Operating frequency is needed for core calculations and wire sizing. Core material is selected for the known operating frequency or frequencies which can be anything from silicon steel laminations to a ferrite core structure. Other bobbin wound transformer design considerations are space limitations and mounting technique. Lead terminations, if needed, may also be specified through the design of a Bobbin Wound Transformer. Bobbin wound transformer designs vary widely in terms of power rating, voltage and current levels (turns ratios), operating frequency, size, impedance, bandwidth (frequency response), packaging, winding capacitance, and other parameters.

Railroad lighting power transformer with custom terminal board.

Power transformer image shows leads coming off the windings.

Side view of power transformer showing (blue) ring tongue connecting wiring to custom board.

Image shows the primary windings (left) and the secondary windings (right).

Surface mount transformers Surface mount transformers may also be wound on a toroidal core and mounted to surface mount header for printed circuit board connection. Surface mount transformers can be designed to operate from 60Hz, or line frequency, well into the MHz range. Where are Surface Mount Transformers found? Surface mount transformers may also be wound on a toroidal core and mounted to surface mount header for printed circuit board connection. Surface mount transformers can be designed to operate from 60Hz, or line frequency, well into the MHz range. Where are Surface Mount Transformers found? Switch mode power supplies. Power conversion applications. Filter circuits Any application that the transformer can be designed on a surface mounted coil form.

Design upper limits of a Surface Mount Transformer: Typical minimum requirements to be specified for a Surface Mount Transformer are o Power rating in VA. o Operating frequency in Hz. Operating frequency is needed for core calculations and wire sizing.

o Operating current levels, DC in Amperes and AC in Amperes peak to peak. o Number of primary windings, voltages & currents. o Number of secondary windings, voltages & currents. o Operating frequency is needed for core calculations and wire sizing. Core material is selected for the known operating frequency or frequencies which can be anything from silicon steel laminations to a ferrite core structure. Another surface mount transformer design consideration is space limitation.

Surface Mount Transformer designs vary widely in terms of power rating, voltage and current levels, operating frequency, size, impedance, bandwidth (frequency response), packaging, winding capacitance, and other parameters

Switch mode power supplies. Power conversion applications. Filter circuits Any application that the transformer can be designed on a surface mounted coil form.

Design upper limits of a Surface Mount Transformer: Typical minimum requirements to be specified for a Surface Mount Transformer are o Power rating in VA. o Operating frequency in Hz. Operating frequency is needed for core calculations and wire sizing. o Operating current levels, DC in Amperes and AC in Amperes peak to peak. o Number of primary windings, voltages & currents. o Number of secondary windings, voltages & currents. o Operating frequency is needed for core calculations and wire sizing. Core material is selected for the known operating frequency or frequencies which can be anything from silicon steel laminations to a ferrite core structure. Another surface mount transformer design consideration is space limitation.

Surface Mount Transformer designs vary widely in terms of power rating, voltage and current levels, operating frequency, size, impedance, bandwidth (frequency response), packaging, winding capacitance, and other parameters. Switch mode power transformers Switch mode power transformers are used extensively in electronic applications, usually within a switch mode power supply: Computer power supplies Cell phone charging units Lighting applications Laser power supply

The specifications of a switching transformer usually includes: Circuit Topology: Flyback, Feed Forward or Blocking Oscillator Power Rating in VA Input Voltage in volts

Peak Input Current in Amps Operating Frequency in kHz Secondary Voltage in volts Secondary Current in Amps

***These specifications are specific to applications. Learn more about switch mode power transformers and switch mode power transformer application circuits. Butler Winding designs switching mode power transformers and inductors for Buck, Flyback, and Boost applications in a wide variety of shapes and sizes. This includes various standard types of core with bobbin structures (E, EP, EFD, PQ, POT, U and others), toroids, and some custom designs. Our upper limits are 40 pounds of weight and 2 kilowatts of power. We have experience with foil windings, litz wire windings, and perfect layering. For toroid transformers, we can sector winding, progressive winding, bank winding, and progressive bank winding. Butler winding has a variety of winding machines, bobbin/tube and toroid. That includes two programmable automated machines and a taping machine for toroids. Butler Winding has vacuum chamber(s) for vacuum impregnation and can also encapsulate. To ensure quality, Butler Winding purchased two programmable automated testing machines. Most of our production is 100% tested on these machines.