{
  "schema": "gallery_item_v1",
  "id": "planar-1kw-gan",
  "title": "Planar Transformer · 1 kW · GaN 500 kHz",
  "topology": "planar",
  "blurb": "380→12 V / 83 A planar PCB-trace TX with 10-layer 2-oz Cu interleaving.",
  "spec": {
    "topology": "planar",
    "p_out_w": 1000,
    "v_in_min": 380,
    "v_in_max": 410,
    "v_out": 12,
    "i_out_max": 83.3,
    "fsw_hz": 500000,
    "delta_t_max_c": 35,
    "isolation_v": 3000,
    "ambient_c": 25,
    "lifetime_years": 10,
    "application": "telecom",
    "rohs": true,
    "notes": "GaN-driven LLC planar 1kW @ 500kHz, 12V/83A bus converter"
  },
  "design": {
    "spec": {
      "topology": "planar",
      "p_out_w": 1000.0,
      "v_in_min": 380.0,
      "v_in_max": 410.0,
      "v_out": 12.0,
      "i_out_max": 83.3,
      "fsw_hz": 500000.0,
      "delta_t_max_c": 35.0,
      "isolation_v": 3000.0,
      "ambient_c": 25.0,
      "lifetime_years": 10.0,
      "application": "telecom",
      "rohs": true,
      "notes": "GaN-driven LLC planar 1kW @ 500kHz, 12V/83A bus converter"
    },
    "core": {
      "pn": "EE_EE25_13_7-TDK_PC200",
      "vendor": "TDK",
      "material": "PC200",
      "shape": "EE",
      "ae_mm2": 52.5,
      "ve_mm3": 3000.0,
      "le_mm": 57.5,
      "aw_mm2": 55.0,
      "al_nh": 504.8,
      "bsat_t_mt": {
        "25": 380.0,
        "60": 345.0,
        "100": 310.0,
        "120": 288.0
      },
      "pcv_steinmetz": {
        "k": 6.934737009050636e-09,
        "alpha": 1.72,
        "beta": 2.65,
        "t_ref_c": 100
      },
      "mu_i": 800.0,
      "f_max_hz": 4000000.0,
      "price_usd": 1.7,
      "rohs": true
    },
    "n_pri": 9,
    "n_sec": 1,
    "wire_pri": {
      "pn": "Litz_20x0_1_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 0.537,
      "od_mm": 0.634,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 20,
      "litz_strand_d_mm": 0.1,
      "price_usd_per_m": 0.476
    },
    "wire_sec": {
      "pn": "Litz_400x0_1_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 2.4,
      "od_mm": 2.832,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 400,
      "litz_strand_d_mm": 0.1,
      "price_usd_per_m": 8.752
    },
    "n_par_pri": 6,
    "n_par_sec": 8,
    "fringing_factor": 1.007,
    "air_gap_mm": 0.007,
    "b_peak_t": 0.2,
    "b_peak_safe": true,
    "pcv_w": 1.486,
    "pcu_w": 1.539,
    "p_total_w": 7.869,
    "eta_est": 0.9922,
    "delta_t_c": 126.7,
    "hotspot_c": 151.7,
    "lk_uh": 40.0,
    "lm_uh": 800.0,
    "cps_pf": 19.87,
    "mtbf_h": 141781.0,
    "pdiv_v": 474.0,
    "pdiv_margin_ok": false,
    "fill_factor": 4.019,
    "bom": [
      {
        "item": "Core",
        "pn": "EE_EE25_13_7-TDK_PC200",
        "vendor": "TDK",
        "qty": 1,
        "price_usd": 1.7,
        "alternatives": []
      },
      {
        "item": "Wire-PRI",
        "pn": "Litz_20x0_1_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 0.34,
        "price_usd_per_m": 0.476
      },
      {
        "item": "Wire-SEC",
        "pn": "Litz_400x0_1_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 0.04,
        "price_usd_per_m": 8.752
      },
      {
        "item": "Bobbin",
        "pn": "BOB-EE-PBT",
        "vendor": "Pretak",
        "qty": 1,
        "price_usd": 0.8
      },
      {
        "item": "Tape (Kapton 0.05mm)",
        "pn": "3M-5413",
        "vendor": "3M",
        "length_m": 1.0,
        "price_usd_per_m": 0.3
      }
    ],
    "warnings": [
      "Using 6 parallel strands of Litz_20x0_1_PEU for I_rms=3.7A.",
      "Using 8 parallel strands of Litz_400x0_1_PEU for I_rms=92.5A.",
      "Loss breakdown: Pcv=1.49W (iGSE), Pcu=1.54W (Dowell+Ferreira), Extras=4.84W (term=3.725W, gap_eddy=0.001W, stray=1.118W, cap=0.0W)",
      "§17 Window overfilled (effective): used_Ku=4.02 > target=0.30 (litz_manual_served, eff_area=17mm² of core.aw=55mm² — 70% lost to bobbin/margin/pins).",
      "⚠️ PDIV E-field corner concentration: F=2.9× → E_local=11858V/mm vs breakdown/2.0=2372V/mm. Margin 0.20 < 1.0. Reference IEC 60664-1.",
      "§13.3 Dowell margin: h/δ=4.7; recommend Tier B FEM to confirm AC resistance.",
      "§11.12 LLC gain insufficient: peak=0.07 < required 0.57 at Vin_min. Increase Lm/Lk ratio or pick smaller Cr.",
      "§11.12 Q=13.29 > 0.8 (heavy-load): gain curve sharp, sensitive to Cr tolerance.",
      "⚠️ §11.11 Ringing overshoot 1410V > 30%·Vbus (123V). Snubber required.",
      "§11.11 Damping ζ=0.000 < 0.1 — under-damped, will ring for many cycles.",
      "⛔ §11.7 Lifetime 0.0y dominated by 'coffin_manson'. Below typical 5-year service requirement.",
      "§11.7 Thermal cycling dominates: ΔT=126.7°C/cycle. Reduce ΔT via better thermal management or pick more compliant potting."
    ],
    "citations": [
      "McLyman, Transformer & Inductor Design Handbook, 4th ed.",
      "Self-study_Hoang.docx §1.2 Fundamentals of Magnetics",
      "Gemini_Claude.md §99.5 (PDIV surrogate, Planar stackup)"
    ],
    "trust_score": 50.0,
    "trust_breakdown": {
      "energy_balance": 20.0,
      "mesh_convergence": 10.0,
      "reference_benchmark": 8.0,
      "datasheet_match": 12.0,
      "lab_measurement": 0.0
    },
    "trust_grade": "B",
    "reliability_matrix": {
      "Lm_pct": 10.0,
      "Lk_pct": 20.0,
      "Pcv_in_range_pct": 25.0,
      "Pcv_dc_bias_pct": 50.0,
      "Rac_near_gap_pct": 50.0,
      "T_hotspot_C": 5.0,
      "EMI_Cps_pct": null,
      "PDIV_margin_pct": null,
      "lifetime_factor": 3.0
    },
    "not_valid_for": [
      "UL 1446 insulation system certification",
      "IEC 61558 / 62368 transformer certification",
      "AEC-Q200 automotive component qualification",
      "CISPR 22/32 EMI compliance claim",
      "Lifetime claim > 5 years without HALT calibration"
    ],
    "uncertainty_envelope": {
      "Lm_uH": {
        "value": 800.0,
        "uncertainty_pct": 10.0,
        "ci_low_2sigma": 640.0,
        "ci_high_2sigma": 960.0,
        "method": "engine→Lm_pct"
      },
      "Lk_uH": {
        "value": 40.0,
        "uncertainty_pct": 20.0,
        "ci_low_2sigma": 24.0,
        "ci_high_2sigma": 56.0,
        "method": "engine→Lk_pct"
      },
      "Pcv_W": {
        "value": 1.486,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 0.743,
        "ci_high_2sigma": 2.229,
        "method": "engine→Pcv_in_range_pct"
      },
      "Pcu_W": {
        "value": 1.539,
        "uncertainty_pct": 50.0,
        "ci_low_2sigma": 0.0,
        "ci_high_2sigma": 3.078,
        "method": "engine→Rac_near_gap_pct"
      },
      "Hotspot_C": {
        "value": 151.7,
        "uncertainty_pct": 3.3,
        "ci_low_2sigma": 141.7,
        "ci_high_2sigma": 161.7,
        "method": "engine→T_hotspot_C"
      },
      "PDIV_V": {
        "value": 474.0,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 237.0,
        "ci_high_2sigma": 711.0,
        "method": "engine→PDIV_margin_pct"
      },
      "Cps_pF": {
        "value": 19.87,
        "uncertainty_pct": 125.82,
        "ci_low_2sigma": -30.13,
        "ci_high_2sigma": 69.87,
        "method": "engine→EMI_Cps_pct"
      },
      "Lifetime_h": {
        "value": 141781.0,
        "uncertainty_pct": 3.0,
        "ci_low_2sigma": 133274.14,
        "ci_high_2sigma": 150287.86,
        "method": "engine→lifetime_factor"
      }
    },
    "validity_warnings": [
      "§13.3 Dowell margin: h/δ=4.7; recommend Tier B FEM to confirm AC resistance."
    ],
    "monte_carlo": {
      "Lm_uH": {
        "metric": "Lm_uH",
        "n_samples": 500,
        "mean": 41.416,
        "stdev": 5.882,
        "p5": 32.1757,
        "p50": 41.8275,
        "p95": 50.3296,
        "cpk_lower": -38.455,
        "cpk_upper": 47.523
      },
      "Pcv_W": {
        "metric": "Pcv_W",
        "n_samples": 500,
        "mean": 1.4868,
        "stdev": 0.1399,
        "p5": 1.2613,
        "p50": 1.4791,
        "p95": 1.7273,
        "cpk_lower": 0.887,
        "cpk_upper": 0.883
      },
      "eta": {
        "metric": "eta",
        "n_samples": 500,
        "mean": 0.9922,
        "stdev": 0.0001,
        "p5": 0.992,
        "p50": 0.9922,
        "p95": 0.9924,
        "cpk_lower": 23.987,
        "cpk_upper": 24.028
      },
      "Hotspot_C": {
        "metric": "Hotspot_C",
        "n_samples": 500,
        "mean": 151.7514,
        "stdev": 2.9236,
        "p5": 147.2241,
        "p50": 151.6216,
        "p95": 156.2641,
        "cpk_lower": 1.735,
        "cpk_upper": 1.724
      },
      "preset": {
        "al_nh_pct": 25.0,
        "gap_mm_abs": 0.05,
        "b_pk_pct": 5.0,
        "steinmetz_k_pct": 10.0
      }
    },
    "llc_tank": {
      "fr_kHz": 500.0,
      "fm_kHz": 109.1,
      "Q": 13.286,
      "k_lm_over_lk": 20.0,
      "gain_min": 0.109,
      "gain_max": 0.07,
      "zvs_ok": true,
      "Cr_recommended_nF": 2.53,
      "notes": [
        "§11.12 LLC gain insufficient: peak=0.07 < required 0.57 at Vin_min. Increase Lm/Lk ratio or pick smaller Cr.",
        "§11.12 Q=13.29 > 0.8 (heavy-load): gain curve sharp, sensitive to Cr tolerance."
      ]
    },
    "inrush": {},
    "advanced_analysis": {
      "bertotti": {
        "P_hysteresis_W_per_m3": 8.7568,
        "P_classical_eddy_W_per_m3": 0.038,
        "P_excess_W_per_m3": 2.846,
        "P_total_W_per_m3": 11.6409,
        "fraction_h": 0.7522,
        "fraction_c": 0.0033,
        "fraction_a": 0.2445,
        "dominant_mechanism": "hysteresis-dominant (low-f regime)"
      },
      "acoustic": {
        "f_acoustic_hz": 1000000.0,
        "in_audible_band": false,
        "spl_db_estimate": 27.0,
        "lambda_s_ppm": -0.5
      },
      "ringing": {
        "f_ring_mhz": 5.65,
        "z_ring_ohm": 1418.83,
        "v_ring_pk": 1409.6,
        "damping_ratio": 0.0,
        "overlaps_emi_band": false,
        "snubber_r_ohm": 1418.83,
        "snubber_c_pf": 59.6
      },
      "aging": {
        "L_total_h": 403.0,
        "L_total_y": 0.0,
        "dominant": "coffin_manson"
      },
      "paschen": {
        "v_breakdown": 12594.0,
        "altitude_derating": 1.0,
        "safe": true
      },
      "humidity": {
        "moisture_uptake_pct": 0.118,
        "pdiv_derate_pct": 0.6,
        "aging_factor": 1.006
      }
    },
    "window_breakdown": {
      "core_window_mm2": 55.0,
      "after_walls_mm2": 65.8,
      "after_margin_mm2": 19.74,
      "after_pin_leadout_mm2": 16.78,
      "deduction_pct": 69.5,
      "wall_loss_mm2": -10.8,
      "margin_loss_mm2": 84.0,
      "margin_note": "margin tape 6.0mm × height=14.0mm",
      "pin_loss_mm2": 1.97,
      "leadout_loss_mm2": 0.99,
      "interleave_loss_mm2": 0.0,
      "bobbin_pn": "PinShine_EE25_8pin",
      "ku_target": 0.3,
      "ku_key": "litz_manual_served",
      "used_ku": 4.019,
      "a_winding_mm2": 67.44
    },
    "bobbin_pn": "PinShine_EE25_8pin",
    "material_score": {
      "loss": 48.7,
      "saturation": 85.5,
      "freq_fit": 100.0,
      "dc_bias": 75.0,
      "acoustic": 100.0,
      "app_match": 90.0,
      "cost": 93.0,
      "availability": 75.0,
      "ap_fit": 94.9,
      "thermal": 30.0,
      "total": 73.6,
      "rationale": [
        "Pcv≈381 mW/cm³ at design point",
        "Bsat margin=35% at 85°C",
        "fsw/f_res=0.05 (f_res≈10000kHz)",
        "no DC bias requirement",
        "f_acoustic=1000000Hz outside audible",
        "telecom-class material",
        "$1.70/qty1k",
        "2 equivalents available",
        "Ap ratio 1.76 oversized",
        "Ve=3000mm³ for 1000W (ratio=0.38)"
      ]
    },
    "top_3_alternatives": [
      {
        "pn": "EE_EE25_13_7-TDK_PC200",
        "vendor": "TDK",
        "material": "PC200",
        "shape": "EE",
        "ae_mm2": 52.5,
        "ve_mm3": 3000.0,
        "score_total": 73.6,
        "score_breakdown": {
          "loss": 48.7,
          "saturation": 85.5,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 90.0,
          "cost": 93.0,
          "availability": 75.0,
          "ap_fit": 94.9,
          "thermal": 30.0,
          "total": 73.6,
          "rationale": [
            "Pcv≈381 mW/cm³ at design point",
            "Bsat margin=35% at 85°C",
            "fsw/f_res=0.05 (f_res≈10000kHz)",
            "no DC bias requirement",
            "f_acoustic=1000000Hz outside audible",
            "telecom-class material",
            "$1.70/qty1k",
            "2 equivalents available",
            "Ap ratio 1.76 oversized",
            "Ve=3000mm³ for 1000W (ratio=0.38)"
          ]
        },
        "rationale": [
          "Pcv≈381 mW/cm³ at design point",
          "Bsat margin=35% at 85°C",
          "fsw/f_res=0.05 (f_res≈10000kHz)",
          "no DC bias requirement",
          "f_acoustic=1000000Hz outside audible",
          "telecom-class material",
          "$1.70/qty1k",
          "2 equivalents available",
          "Ap ratio 1.76 oversized",
          "Ve=3000mm³ for 1000W (ratio=0.38)"
        ]
      },
      {
        "pn": "PQ_PQ35_35-Ferroxcube_3F45",
        "vendor": "Ferroxcube",
        "material": "3F45",
        "shape": "PQ",
        "ae_mm2": 196.0,
        "ve_mm3": 13300.0,
        "score_total": 67.3,
        "score_breakdown": {
          "loss": 53.1,
          "saturation": 87.5,
          "freq_fit": 98.8,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 90.0,
          "cost": 52.2,
          "availability": 25.0,
          "ap_fit": 20.0,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈311 mW/cm³ at design point",
          "Bsat margin=38% at 85°C",
          "fsw/f_res=0.06 (f_res≈8889kHz)",
          "no DC bias requirement",
          "f_acoustic=1000000Hz outside audible",
          "telecom-class material",
          "$7.60/qty1k",
          "single-source material — supply risk",
          "Ap ratio 13.82 much oversized",
          "Ve=13300mm³ for 1000W (ratio=1.66)"
        ]
      },
      {
        "pn": "Planar_EL_ELP64_10_50-Ferroxcube_3F45",
        "vendor": "Ferroxcube",
        "material": "3F45",
        "shape": "Planar",
        "ae_mm2": 519.0,
        "ve_mm3": 22000.0,
        "score_total": 66.8,
        "score_breakdown": {
          "loss": 53.1,
          "saturation": 87.5,
          "freq_fit": 98.8,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 90.0,
          "cost": 41.1,
          "availability": 25.0,
          "ap_fit": 20.0,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈311 mW/cm³ at design point",
          "Bsat margin=38% at 85°C",
          "fsw/f_res=0.06 (f_res≈8889kHz)",
          "no DC bias requirement",
          "f_acoustic=1000000Hz outside audible",
          "telecom-class material",
          "$11.30/qty1k",
          "single-source material — supply risk",
          "Ap ratio 41.02 much oversized",
          "Ve=22000mm³ for 1000W (ratio=2.75)"
        ]
      }
    ]
  },
  "kpi": {
    "eta_pct": 99.22,
    "trust_grade": "B",
    "trust_score": 50.0,
    "core_pn": "EE_EE25_13_7-TDK_PC200",
    "bobbin_pn": "PinShine_EE25_8pin",
    "n_pri": 9,
    "n_sec": 1,
    "air_gap_mm": 0.007,
    "p_total_w": 7.87,
    "hotspot_c": 151.7,
    "b_peak_t": 0.2
  },
  "screenshot_path": "/marketing/gallery/planar-1kw-gan.png",
  "deep_link": "/calculator?gallery=planar-1kw-gan",
  "engine_version": "v1.8.0+day3_audit",
  "generated_at": "2026-05-23T05:10:14Z"
}