ClickEle Power Transformers

ClickEle power transformer efficiency varies by product series and operating conditions: (1) Small signal transformers (1-10W) - 85-92% efficiency

(2) Medium power transformers (10-100W) - 92-96% efficiency

(3) High power transformers (100W-1kW) - 96-98% efficiency

(4) Efficiency depends on load - typically peaks at 50-75% load

(5) Core material affects efficiency - amorphous cores offer 20-30% lower loss than ferrite at high frequency. Losses include core loss (hysteresis and eddy current) and copper loss (winding resistance). For high-efficiency designs, ClickEle offers amorphous and nanocrystalline core options.

Select transformer with efficiency rating matching your application requirements. Amorphous cores for premium efficiency.

Transformer temperature rise calculation: (1) Total losses = Core loss + Copper loss

(2) Core loss from datasheet at operating flux density and frequency

(3) Copper loss = I² × DCR (primary and secondary)

(4) Temperature rise = Total losses × Thermal resistance

(5) Typical thermal resistance 20-40°C/W for small transformers, 5-15°C/W for large transformers with heatsinking. Example: 10W losses with 20°C/W thermal resistance = 200°C rise (unacceptable). Solutions: (1) Increase conductor size to reduce copper loss

(2) Select lower loss core material

(3) Improve thermal design with heatsink or forced air

(4) Use larger core size to reduce flux density.

Calculate temperature rise during design phase. Ensure maximum temperature stays within insulation class limits.

ClickEle transformers carry major international safety certifications: (1) UL 5085 - US standard for low voltage transformers

(2) IEC 61558 - International safety standard for power transformers

(3) VDE 0570 - German safety standard

(4) TUV - European safety certification

(5) CCC - China Compulsory Certification

(6) CE - European conformity marking

(7) UL 1446 - Insulation systems recognition. Transformers are designed with appropriate creepage and clearance distances for reinforced or basic isolation. Certification files and test reports are available for each product series. Custom transformers can be designed to meet specific safety requirements.

Verify required certifications for your market. ClickEle can provide certified transformers for most global markets.

ClickEle flyback and forward transformers have different designs: (1) Flyback - energy stored in core during on-time, delivered to output during off-time, air gap required in core, simpler design, good for <150W, higher peak currents

(2) Forward - energy transferred directly during on-time, no air gap, requires reset winding or diode, better for higher power, lower peak currents

(3) Flyback uses single winding for each output, forward needs separate rectifier for each output

(4) Flyback has discontinuous secondary current, forward has continuous current. ClickEle offers both types optimized for their respective topologies with proper gap design for flyback and tight coupling for forward.

Use flyback for <150W and cost-sensitive designs. Use forward for higher power and better efficiency.

For custom transformer specifications, provide ClickEle with: (1) Input voltage range - nominal, minimum, maximum

(2) Output requirements - voltage, current, regulation, number of outputs

(3) Power rating - continuous and peak power

(4) Switching frequency - operating frequency and topology

(5) Size constraints - maximum dimensions

(6) Temperature requirements - ambient range and max temperature rise

(7) Isolation requirements - working voltage, test voltage, creepage/clearance

(8) Safety standards - required certifications

(9) Quantities - prototype and production volumes. ClickEle engineering team can optimize the design for cost, size, or efficiency based on your priorities. Typical custom design cycle is 2-4 weeks for prototypes.

Contact LiTong FAE with your specifications for custom transformer design support.