The resonant transformer inside an 11-22 kW EV onboard charger runs at hundreds of kilohertz, and it decides more than any other single component whether the charger ends up small, cool and efficient – or none of those. This article walks through the shift from wire-wound to planar PCB-integrated magnetics: why higher switching frequency shrinks the core, which materials survive 200-500 kHz, how interleaved windings tame leakage inductance, and the manufacturing tolerances that separate a working design from a hot one.
Category: Insights
Laminated, Toroidal, or Ferrite: Choosing a Transformer Core
A practical primer on choosing between laminated silicon-steel, toroidal, and ferrite transformer cores by frequency, power, size, and EMI.