Comparison of Design Types

PCB Direct Mounting
EI or UI laminated core, optimized for low to medium power ratings. Minimal assembly effort thanks to direct soldering. Ideal for compact switching power supply designs and mass production with tight cost constraints.
High Efficiency & EMC
Closed magnetic circuit with directly mounted windings. Low stray field, high efficiency, and low noise—the preferred choice for EMC-critical environments and audiophile applications.

Typical Areas of Application

Power Supplies and Chargers · Industrial Control Systems and PLCs · Measuring Instruments and Sensor Technology · Lighting Systems (DALI, TRIAC) · Medical Devices (Galvanic Isolation) · Drive Technology and Servo Inverters

Materials & Components

  • Winding wire
    Enamel-insulated copper wire (high conductivity); aluminum as an alternative for weight- or cost-optimized designs
  • Core Material (50/60 Hz)
    Soft magnetic silicon steel sheets—reduce magnetization losses in the mains frequency range
  • Core material (HF)
    Ferrite cores – lower eddy current losses at higher switching frequencies (SMPS, LLC, flyback)
  • Coil formers
    Temperature-resistant plastics (polyamide, PBT)—provide electrical insulation and mechanical dimensional stability

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Designs, Materials, and Components

PCB transformers are compact designs intended for direct mounting on printed circuit boards. They typically feature an EI- or UI-type laminated core and are suitable for low- to medium-power applications. Their advantages include easy integration, low installation costs, and compact dimensions.

Toroidal transformers use a closed, ring-shaped core onto which the windings are directly applied. The closed magnetic circuit results in low stray fields, high efficiency, and a compact design. They are particularly well-suited for applications with high demands for efficiency, low noise, and minimal electromagnetic interference.

Enamel-insulated copper wire is predominantly used for the windings, as copper has high electrical conductivity. In cost- or weight-optimized applications, aluminum may also be used.

The coil form serves to house the windings, provide electrical insulation, and ensure mechanical stability. Typical materials include heat-resistant plastics such as polyamide or PBT.

Soft magnetic electrical steel sheets made of silicon steel are usually used as core materials. These reduce magnetization losses. Ferrite cores are used for higher frequencies because they exhibit lower eddy current losses.

For customer-specific requirements, various properties can be specifically designed:

  1.  Output Voltage and Power
  2.  Efficiency and losses
  3.  Design and Dimensions
  4.  Thermal behavior
  5.  EMC Properties 
  6.  Safety Requirements
  7.  Connection Options
  8.  Noise Level
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Custom Transformers

Voltage regulation, galvanic isolation, thermal performance—the requirements for modern transformers are diverse. With in-depth application expertise and flexible manufacturing, we develop the right solution for your control, drive, or measurement technology: efficient, compliant with standards, and ready for series production.