2017 IEEE 23rd International Symposium for Design and Technology in Electronic Packaging (SIITME)

A Study of Losses in Planar Transformers with

Different Layer Structure

Constantin Ropoteanu, Paul Svasta and Ciprian Ionescu

Center of Technological Electronics and Interconnection Techniques
Politehnica University of Bucharest
Romania
constantin.ropoteanu@cetti.ro

Abstract—Planar transformers in DC-to-DC converters are The second proposed transformer model has the secondary
attractive due to compactness at high power applications. winding disposed in four layers with one single turn that
Usually, converters work in the sub-MHz range and naturally the connects with the next one through vias. For both transformer
questions of losses both in-core and in-winding appears. The models secondary winding are center taped according to the
present work provides a comparative analysis of winding losses push-pull topology requirements.
in two types of planar transformer PCB stack structure. The
study aims to analyze the influence of winding arrangement on a
step-up planar transformer over the leakage inductance based on
the magneto motive force. The results show the impact of losses
on the full converter in two FR4 structure embodiments: one
with the secondary on a single inner layer and the second with
the winding in multiple layers. For this approach a planar core
transformer was modeled for sub-MHz range (0.4 – 1.0 MHz)
analysis.

Keywords—planar transformers, PCB structure, converter Fig.1: Two layer four turns secondary winding model
I. INTRODUCTION appearance with centre tap.
The use of planar transformers in power supply systems can
have an important contribution into obtaining high efficiency.
With the small winding area of planar transformers,
maximization of the potential of winding and core is essential
[1]. Winding arrangement in the PCB stack can generate
parasitic due to the trace thickness, layer spacing, frequency of
operation and the number of used turns [2]. Not all the
magnetic flux generated by AC current excitation on the
primary side follows the magnetic circuit and link with other
windings [3]. In analogy with [4], when traces are connected in
parallel, adding skin and proximity losses of individual wires, Fig.2: Four layer two turns secondary winding model
give the total copper losses only if the currents flowing in all appearance with centre tap.
the wires connected in parallel are really equal. In addition, the
stored energy in the leakage inductance leads to the generation
of voltage spikes on the main switch, besides creating EMI
problems, increases the switching losses and lowers the II. LOSSES IN HIGH FREQUENCY POWER TRANSFORMERS
efficiency [5]. Power supply EMI and control problems In general terms, parasitic capacity is a distributed capacity
concerns sensitive and complex devices used in embedded due to the proximity between two conductors at different
systems [6][7]. electrical potentials, printed wiring paths in this work. The
The purpose of the study is to estimate the efficiency of types of parasitic capacities that influence the magnetic
components are: the capacities between the windings, the
modeled structures considering the distribution of both the field
capacities between spirals and those between the windings and
strength along magnetic flux path and magnetomotive force.
The obtained simulated results will be an important step onto the magnetic core. The capacitance that can occur between the
windings of a transformer usually conducts to parallel
the estimation of leakage inductance. Figure 1 illustrates layer
resonances or leakage inductance in the magnetic component.
distribution for the secondary winding of the first proposed
planar transformer model. In this case the winding is disposed Considering the conservation of energy, at any moment of
in two inner layers with a symmetrical four turns arrangement. time, the current within the conductors and the magnetic field

978-1-5386-1626-0/17/$31.00 ©2017 IEEE  26-29 Oct 2017, Constanța, Romania

 2017 IEEE 23rd International Symposium for Design and Technology in Electronic Packaging (SIITME)
are distributed so as to minimize the energy taken from the
source [8]. The characterization of switching transformers
losses can be made starting from the magnetic field
fundamental components, considering magnetomotive force
and the energy stored in the magnetic field. The Ampere's law
states that the magnetic potential along any closed conduction
path is equal to the total current enclosed by the path, being
mathematically described by the relation:
(1)
where F is the magnetic potential along the path l
H is the magnetic field intensity, N is the number of
turns and I is the current carried by the path.
The expression that defines the total magnetic energy
in a system within l inductors that are mutual coupled is:
(2)
Following good practice rules dictated by an iterative
process, the undesirable energy stored in a planar transformer
that leads to parasitic leakage, can be minimized by a reduced
number of turns, interleaving windings and using an
appropriate core.
III. SIMULATION APPROACH
According to [9], the spaces of the equipotential surfaces,
that describe the magnetic force, form the magnetic potential
force gradient H.
Two planar transformer models are proposed for the present
approach, both PCB stacks being modeled with six layers
having the winding ratio of 1:2 and 1:4. In figure 3 primary
winding consists of a single turn, its layout distribution being
drawn in four layers. It can be seen that the four layers that
define the primary winding have a greater current carried
capacity which lead to an additional care regarding the
inequality of current distribution on every layer. Moreover, it is
of interest to determine correctly the number of vias that may
carry the current from one layer to another.
Fig.3: Two layer four turns secondary stack arrangement (T1)
978-1-5386-1626-0/17/$31.00 ©2017 IEEE
Fig.4: Four layer two turns secondary winding model
appearance with center tap (T2).
Second proposed transformer stack model, indicated in
figure 4, shows an opposite situation in which the secondary
center taped winding has a four layer with two turns, according
to the specific winding in a push-pull transformer topology. A
similar situation becomes of interest also for this model that
relates to via type that will provide an appropriate current from
one layer to another.
Nevertheless, due to the arrangement of windings the
magnetic flux that links may be limited by the adjacent leakage
fluxes that do not link all the turns. It was shown in [8] that the
magnetomotive force has a linearly variation with distance
from a minimum value that lives in the inner of winding to a
maximum value near to the core center.
Therefore, energy stored in the magnetic field, consider the
volume of winding can be described by following relation:
(3)
where bw is the winding breadth and lw winding mean turn
length.
Also the magnetic field intensity along the flux path is
proportional with the number of ampere turns considering a
single layer having thickness dx which is located at a distance x
from the inner surface of winding:
(4)
where s is the distance of the flux path and the product NI
describes the ampere turn magnitude.
Both transformer models have the secondary windings as
inner layers. The turn’s arrangement would be P-P-S-S-P-P-
for figure 3 and P-S-S-S-S-P for figure 4. Using the finite
element analysis, based on the field strength distribution in
windings, although it was shown in [10] that magnetomotive
force has a linearly variation, increasing frequency may imply
also a greater magnitude of losses caused by leakage
inductance. Energy distribution in layers varies with the square
of the field intensity H and depends on the layout. This implies
winding breadth and turns number.
 26-29 Oct 2017, Constanța, Romania
 2017 IEEE 23rd International Symposium for Design and Technology in Electronic Packaging (SIITME)
In order to determine the magnitude of the field energy in on the secondary winding of the T2 transformer model, in
windings the solver’s frequency was 700 kHz and magnetic which case the turns have a large scale due to the permissive
properties were assigned to the magnetic core model for 3F4 winding breadth.
material (Table 1).

TABLE I. MAGNETIC MATERIAL PROPERTIES

Magnetic material T1
Properties 3F4
Relative permeability 1500
Cm 12·10-4
Corel loss [W/m3] X 1.75
Y 2.9
T2

Core model properties were applied in both transformer

models analyses.
Fig.6: Magnetic field magnitude in the secondary windings
IV. SIMULATION RESULTS

Using the eddy current solution setup both primary and Regarding the H field distribution and in order to relieve
secondary windings were analyzed. It is to be mentioned that the behavior of both models, energy distribution simulation
for this approach the primary windings carry twice the current results were plotted for the secondary windings (figure 7).
was applied to secondary, meaning 10A. Transformer models
excitation currents are not absolute values, in which case the
approach aims to determine how will affect one turn
arrangement or another the transformer efficiency. T1
Due to the fact that magnetic field intensity along the flux
path depends on the number of ampere turns primary windings
simulations results were plotted using the same reference scale
(figure 5).

T2
T1

Fig.7: Energy field magnitude in the secondary windings

In fact, energy distribution on both planar transformer layer

T2
Fig.5: Magnetic field magnitude in the primary windings
T1 transformer model has a four layer two turns primary
and it can be observed that the average magnetic field has
superior value than in the case of T2 model. With respect to the
current distribution in a transformer, eddy effect may increase
the current density towards the surface of the conductor that
faces the nearest turn. A similar effect is also visible for the
secondary winding of the same transformer T1 (figure 6). This
winding has all four turns on the same layer which would cause
a higher field density. Lower field average value can be seen
stacks is a consequence of the current density with all the
effects produced by the variation of field. In figure 7,
considering the same graphic scale, T1 average value reaches
almost entirely red. In case of T2, taking into account a larger
space for winding and the inner distribution of turns, colder
graphics shows a mended energy distribution on every turn.
In relation with the already obtained simulation results
magnetomotive force distribution for both transformer models
are illustrated in figure 8 and figure 9. The magnetic potential
distribution for T1 indicates higher levels of MMF near the
transformer core center which may lead to increased value of
leakage inductance. Green rectangular shapes describe the PCB
stack isolation and orange represents the copper.

978-1-5386-1626-0/17/$31.00 ©2017 IEEE  26-29 Oct 2017, Constanța, Romania

 2017 IEEE 23rd International Symposium for Design and Technology in Electronic Packaging (SIITME)
Fig.8: Magnetomotive force distribution for T1 transformer
The way the energy is stored in T2 transformer model was
confirmed by the graphics indicated in figure 7. This approach
leads to the fact that interleaved or at least inner distribution of
windings may reduce the influence of leakage inductance.
Fig.9: Magnetomotive force distribution for T2 transformer
Of course, the result is strongly influenced by an
appropriate design of vias in order to equalize the current in
layers that form the winding.
V. CONCLUSIONS
The efficiency of a planar transformer structure depends on
several aspects that are related, considering the working
frequency, to core geometry, number of turns, the arrangement
of layers and thickness of copper tracks. The paper compares
two proposed layer structures considering the energy
distribution in both types of windings. Finite Element Analysis
was chosen for this approach due to an important estimation of
models behavior, although real working conditions will
consider magnetic material manufacturing losses that may vary
with temperature.
978-1-5386-1626-0/17/$31.00 ©2017 IEEE
In this work it was shown that for different winding
arrangement in a planar transformer, the way that energy
distributes determines the magnetomotive force distribution.
Higher levels of stored energy in the windings leads to
increased leakage inductance the transformer, meaning a lower
system efficiency in most of the hard switching applications.
Finally, the second model transformer has a slight
improvement considering the distribution of the secondary
turns in the inner layers of the PCB stack.
ACKNOWLEDGMENT
Authors would like to thank Tensor SRL for making
available and supporting the use of Ansys applications in the
research process.
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