{"id":16696,"date":"2026-09-14T09:00:00","date_gmt":"2026-09-14T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?p=16696"},"modified":"2026-08-26T05:11:40","modified_gmt":"2026-08-26T03:11:40","slug":"how-to-achieve-low-leakage-inductance-and-high-frequency-performance-in-dc-dc-converter-transformers-with-tps-interleaved-and-litz-wire-winding-process","status":"publish","type":"post","link":"https:\/\/tps-elektronik.com\/en\/how-to-achieve-low-leakage-inductance-and-high-frequency-performance-in-dc-dc-converter-transformers-with-tps-interleaved-and-litz-wire-winding-process\/","title":{"rendered":"How to Achieve Low Leakage Inductance and High Frequency Performance in DC-DC Converter Transformers with TPS Interleaved and Litz Wire Winding Process?"},"content":{"rendered":"<article class=\"blog-post\" lang=\"en\"><header>\n<p>For system integrators, electrical engineers, and procurement teams designing high-frequency DC-DC converters, the transformer is not a commodity. It is the component that determines conversion efficiency, EMI performance, and power density. A transformer with excessive leakage inductance wastes energy, generates heat, and radiates electromagnetic interference that can fail EMC testing. In resonant converters and soft-switching topologies, leakage inductance that is too high or too variable can prevent zero-voltage switching (ZVS). Which reducing efficiency and increasing stress on switching devices.<\/p>\n<p>TPS Elektronik&#8217;s <strong>transformer winding manufacturing process<\/strong> addresses these challenges through two proven techniques: <strong>interleaved winding<\/strong> to minimize leakage inductance. And <strong>Litz wire winding<\/strong> to reduce high-frequency losses. From design support through automated CNC winding, insulation, impregnation, and documented testing, TPS delivers production-ready magnetic components with the consistent performance that high-frequency DC-DC converters demand.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/winding-goods\/\">Request a transformer winding manufacturing quote \u2192<\/a><\/p>\n<\/header><nav class=\"toc\" aria-label=\"Table of contents\">\n<h2 id=\"toc\">Table of Contents<\/h2>\n<ol>\n<li><a href=\"#leakage-inductance\">Leakage Inductance: The Hidden Performance Killer in DC-DC Converters<\/a><\/li>\n<li><a href=\"#interleaved-winding\">Interleaved Winding: The Solution to Leakage Inductance<\/a><\/li>\n<li><a href=\"#litz-wire\">Litz Wire: Overcoming Skin and Proximity Effects at High Frequencies<\/a><\/li>\n<li><a href=\"#tps-process\">The TPS Transformer Winding Manufacturing Process<\/a><\/li>\n<li><a href=\"#quality-testing\">Quality and Testing: Ensuring Consistent Performance<\/a><\/li>\n<li><a href=\"#faq\">FAQ<\/a><\/li>\n<\/ol>\n<\/nav>\n<section id=\"leakage-inductance\">\n<h2>1. Leakage Inductance: The Hidden Performance Killer in DC-DC Converters<\/h2>\n<p>Leakage inductance is the magnetic flux that does not couple between the primary and secondary windings of a transformer. In an ideal transformer, all flux links both windings. In the real world, some flux leaks through the air or insulation between windings. Which creating a series inductance that appears in the circuit model.<\/p>\n<p>For high-frequency DC-DC converters, leakage inductance has several detrimental effects:<\/p>\n<ul>\n<li><strong>Energy loss:<\/strong> Leakage inductance stores energy that must be dissipated or recovered, reducing converter efficiency<\/li>\n<li><strong>Voltage spikes:<\/strong> When switching devices turn off, the energy stored in leakage inductance creates voltage transients that stress semiconductors and increase EMI<\/li>\n<li><strong>EMI generation:<\/strong> The ringing caused by leakage inductance interacting with parasitic capacitances radiates electromagnetic interference<\/li>\n<li><strong>Soft-switching failure:<\/strong> In resonant converters and LLC topologies, leakage inductance that is too high or inconsistent prevents ZVS, reducing efficiency<\/li>\n<\/ul>\n<p>The challenge is particularly acute at higher switching frequencies, where even small leakage inductances represent significant impedance. As power density demands increase and converters push into the hundreds of kilohertz or megahertz range, leakage inductance becomes a primary design constraint.<\/p>\n<p>For procurement teams and engineers evaluating <strong>transformer winding manufacturing process<\/strong> capabilities, the ability to consistently achieve low leakage inductance is a key differentiator. TPS Elektronik&#8217;s approach\u2014combining interleaved winding geometry with Litz wire\u2014addresses this challenge at both the structural and material levels.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14612\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57081.jpg\" alt=\"transformer coil winding\" width=\"1920\" height=\"1280\" srcset=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57081.jpg 1920w, https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57081-600x400.jpg 600w\" sizes=\"(max-width: 1920px) 100vw, 1920px\" \/><\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/winding-goods\/\">Learn more about TPS transformer winding manufacturing \u2192<\/a><\/p>\n<\/section>\n<section id=\"interleaved-winding\">\n<h2>2. Interleaved Winding: The Solution to Leakage Inductance<\/h2>\n<p>Interleaved winding is a transformer construction technique where primary and secondary winding segments are alternately layered, rather than placed as discrete blocks. This arrangement maximizes magnetic coupling between the windings and minimizes the flux that escapes as leakage.<\/p>\n<p>In a conventional winding arrangement, the primary and secondary windings are wound as separate blocks on the bobbin. The magnetic field between these blocks creates significant leakage flux. In an interleaved design, the primary winding is split into sections, and the secondary winding placed between them\u2014or vice versa. Which creating a structure where every primary turn is magnetically close to a secondary turn.<\/p>\n<p>The benefits of interleaved winding for <strong>low leakage inductance transformer<\/strong> design are substantial:<\/p>\n<ul>\n<li><strong>Up to 98.9% leakage inductance reduction:<\/strong> Research has demonstrated that interleaved winding can reduce leakage inductance by nearly two orders of magnitude compared to conventional winding designs<\/li>\n<li><strong>Improved coupling:<\/strong> Tighter magnetic coupling means more efficient energy transfer and less stored energy in the leakage path<\/li>\n<li><strong>Better load regulation:<\/strong> Lower leakage inductance reduces voltage drop under load. Which improving regulation across the operating range<\/li>\n<li><strong>Reduced EMI:<\/strong> Less ringing at switching transitions means lower radiated and conducted emissions<\/li>\n<\/ul>\n<p>Interleaving can be implemented in multiple configurations\u2014primary split, secondary split, or fully interleaved layers\u2014depending on the specific transformer requirements. For flyback converters, where leakage inductance directly affects the voltage spike across the primary switch. Which interleaved winding is particularly valuable.<\/p>\n<p>TPS Elektronik&#8217;s multi-axis CNC winding machines are capable of producing complex interleaved winding patterns with the consistency required for series production. The winding program, once validated, delivers identical winding geometry on every unit\u2014a level of repeatability that manual winding cannot achieve.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14559\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57083.jpg\" alt=\"coil winding technology\" width=\"1920\" height=\"1280\" srcset=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57083.jpg 1920w, https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57083-600x400.jpg 600w\" sizes=\"(max-width: 1920px) 100vw, 1920px\" \/><\/p>\n<\/section>\n<section id=\"litz-wire\">\n<h2>3. Litz Wire: Overcoming Skin and Proximity Effects at High Frequencies<\/h2>\n<p>At high switching frequencies, conventional solid wire exhibits <strong>skin effect<\/strong>\u2014the tendency of AC current to concentrate near the conductor surface, effectively reducing the usable cross-sectional area and increasing resistance. <strong>Proximity effect<\/strong>\u2014the interaction of magnetic fields between adjacent conductors\u2014further increases AC resistance, particularly in tightly wound transformer coils.<\/p>\n<p><strong>Litz wire<\/strong> (from the German &#8220;Litzendraht,&#8221; meaning braided or stranded wire) addresses these losses by using <strong>multiple individually insulated strands<\/strong> woven or braided together in a specific pattern. Each strand is thin enough that skin effect is minimal at the operating frequency, and the transposition of strands ensures that each strand occupies different positions within the bundle. Which equalizing current distribution and minimizing proximity effect losses.<\/p>\n<p>For <strong>high-frequency DC-DC transformer<\/strong> applications, Litz wire offers several advantages:<\/p>\n<ul>\n<li><strong>Reduced AC resistance:<\/strong> Litz wire can reduce high-frequency winding losses by 50% or more compared to solid wire of the same cross-sectional area<\/li>\n<li><strong>Lower temperature rise:<\/strong> Reduced losses mean less heat generation, improving transformer reliability and allowing higher power density<\/li>\n<li><strong>Better efficiency:<\/strong> Lower winding losses translate directly to higher converter efficiency\u2014particularly important in applications where every percentage point matters<\/li>\n<li><strong>Flexibility in design:<\/strong> Litz wire can specified with different strand counts, strand diameters, and insulation types to match specific frequency and current requirements<\/li>\n<\/ul>\n<p>The selection of Litz wire parameters\u2014strand count, strand gauge, and twist pitch\u2014must optimized for the specific switching frequency and current waveform. TPS Elektronik&#8217;s engineering team provides <strong>DFM (Design for Manufacturing) feedback<\/strong> to ensure that the wire specification matches both electrical requirements and production feasibility.<\/p>\n<p>For <strong>isolated DC-DC transformer winding<\/strong> applications, the combination of interleaved geometry and Litz wire addresses both magnetic and conductor losses. Which delivering transformers that achieve both low leakage inductance and low AC resistance.<\/p>\n<\/section>\n<section id=\"tps-process\">\n<h2>4. The TPS Transformer Winding Manufacturing Process<\/h2>\n<p>TPS Elektronik&#8217;s <strong>transformer winding manufacturing process<\/strong> combines automated precision winding, comprehensive quality control. And integration with broader EMS capabilities to deliver production-ready magnetic components.<\/p>\n<p><strong>Engineering and Design Support:<\/strong><\/p>\n<ul>\n<li><strong>Core and wire selection:<\/strong> Guidance on ferrite or powder core materials, wire gauges, and insulation systems based on application requirements<\/li>\n<li><strong>Interleaved winding geometry:<\/strong> Design of primary\/secondary layer arrangements to minimize leakage inductance while maintaining manufacturability<\/li>\n<li><strong>Litz wire specification:<\/strong> Determination of strand count, gauge, and insulation for optimal high-frequency performance<\/li>\n<li><strong>Creepage and clearance planning:<\/strong> Margin tape placement and bobbin design to meet IEC 62368-1 and other safety standards<\/li>\n<\/ul>\n<p><strong>Automated Winding:<\/strong><\/p>\n<ul>\n<li><strong>Multi-axis CNC winding:<\/strong> Precise wire placement with dynamically controlled tension to prevent wire stretch and insulation damage<\/li>\n<li><strong>Interleaved winding capability:<\/strong> Complex layer sequences with consistent interleaving across production volumes<\/li>\n<li><strong>Litz wire handling:<\/strong> Specialized winding equipment capable of handling Litz wire without damaging the individual strand insulation<\/li>\n<li><strong>Toroidal and bobbin winding:<\/strong> Flexible winding platforms for different core geometries and form factors<\/li>\n<\/ul>\n<p><strong>Insulation and Impregnation:<\/strong><\/p>\n<ul>\n<li><strong>Inter-layer insulation:<\/strong> Precise placement of margin tape and insulation materials to meet creepage requirements<\/li>\n<li><strong>Impregnation and potting:<\/strong> Optional encapsulation to improve mechanical stability, thermal performance, and environmental protection<\/li>\n<li><strong>Triple-insulated wire (TIW):<\/strong> Available for applications requiring reinforced isolation without additional insulation layers<\/li>\n<\/ul>\n<p><strong>Termination and Assembly:<\/strong><\/p>\n<ul>\n<li><strong>Pin and leadframe integration:<\/strong> Termination of winding ends to pins, leads, or terminals ready for PCB assembly<\/li>\n<li><strong>Custom connectors:<\/strong> Integration of custom connectors or wire harnesses as required<\/li>\n<\/ul>\n<p>TPS Elektronik&#8217;s <strong>coil winding service<\/strong> operates as a production-oriented workflow, not a prototype-only capability. Once a winding program is validated, the same process is repeatable across production volumes\u2014ensuring that the first transformer and the thousandth transformer are electrically and mechanically identical.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-17128\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/08\/Leakage-Inductance-Comparison-Interleaved-vs-Conventional-Winding-3.jpg\" alt=\"Leakage Inductance Comparison Interleaved vs Conventional Winding Vergleich der Streuinduktivit\u00e4t: Verschachtelte vs. konventionelle Wicklung\" width=\"1920\" height=\"1079\" \/><\/p>\n<\/section>\n<section id=\"quality-testing\">\n<h2>5. Quality and Testing: Ensuring Consistent Performance<\/h2>\n<p>For high-frequency DC-DC converter transformers, quality is not just about meeting nominal specifications\u2014it is about consistency across production volumes. A transformer that performs well on the bench but varies in leakage inductance or winding resistance from unit to unit creates field reliability issues that are expensive to diagnose and correct.<\/p>\n<p>TPS Elektronik&#8217;s quality assurance for <strong>transformer winding manufacturing<\/strong> includes:<\/p>\n<p><strong>In-Process Inspection:<\/strong><\/p>\n<ul>\n<li>Winding tension monitoring during automated winding to detect variations that could affect insulation integrity or electrical performance<\/li>\n<li>Layer alignment verification to ensure interleaved geometry is consistent from unit to unit<\/li>\n<li>Insulation placement inspection to verify margin tape and inter-layer insulation are correctly positioned<\/li>\n<\/ul>\n<p><strong>End-of-Line Testing:<\/strong><\/p>\n<ul>\n<li><strong>DCR measurement:<\/strong> Verification of DC resistance against specification to detect variations in wire gauge or winding tension<\/li>\n<li><strong>Inductance (L) and Q factor:<\/strong> Measurement at the operating frequency to verify core assembly and winding integrity<\/li>\n<li><strong>Polarity test:<\/strong> Verification of correct winding orientation for proper phase relationships in the converter circuit<\/li>\n<li><strong>Hipot (dielectric withstand):<\/strong> High-voltage testing to verify insulation integrity and isolation performance<\/li>\n<li><strong>Insulation resistance (IR):<\/strong> Measurement of insulation resistance to detect contamination or insulation damage<\/li>\n<li><strong>Surge testing:<\/strong> Optional test to detect turn-to-turn insulation weakness<\/li>\n<\/ul>\n<p><strong>Documentation:<\/strong><\/p>\n<ul>\n<li><strong>Material certificates:<\/strong> Full traceability of core materials, wire, and insulation components<\/li>\n<li><strong>Test reports:<\/strong> Documented test results for each production batch, including DCR, L\/Q, hipot, and IR values<\/li>\n<li><strong>Serialization:<\/strong> Unique identifiers on each transformer for traceability to production records and test results<\/li>\n<\/ul>\n<p>For <strong>high efficiency DC-DC converter transformer winding<\/strong> applications, this quality framework provides the confidence that every transformer meets the required specifications\u2014from the first prototype through high-volume production.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/winding-goods\/\">Request a transformer winding manufacturing RFQ in 24\u201348 hours \u2192<\/a><\/p>\n<\/section>\n<section id=\"faq\">\n<h2>6. FAQ<\/h2>\n<div>\n<div>\n<h3>What is interleaved winding and why does it reduce leakage inductance?<\/h3>\n<div>\n<div>Interleaved winding is a transformer construction technique where primary and secondary winding segments are alternately layered rather than placed as discrete blocks. This arrangement maximizes magnetic coupling between windings and minimizes flux that escapes as leakage. Research has demonstrated leakage inductance reductions of up to 98.9% with interleaved winding compared to conventional designs.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>When should Litz wire be used in transformer winding?<\/h3>\n<div>\n<div>Litz wire should be used when operating frequencies exceed approximately 50 kHz, where skin effect and proximity effect significantly increase AC resistance in solid conductors. Litz wire&#8217;s multiple insulated strands reduce both skin and proximity effect losses, improving efficiency and reducing temperature rise in high-frequency transformers. TPS provides DFM guidance on Litz wire specification for specific frequency and current requirements.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>What is the difference between leakage inductance and magnetizing inductance?<\/h3>\n<div>\n<div>Magnetizing inductance is the inductance that produces the core flux\u2014the flux that couples both windings. Leakage inductance is the inductance associated with flux that does not couple between windings, appearing as a series inductance in the circuit model. Leakage inductance stores energy that is not transferred to the output, reducing efficiency and creating voltage spikes and EMI. Interleaved winding minimizes leakage inductance by improving magnetic coupling.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>Can TPS manufacture transformers for LLC resonant converters?<\/h3>\n<div>\n<div>Yes. TPS manufactures transformers for LLC resonant converters and other soft-switching topologies. For LLC converters, the combination of interleaved winding (for low leakage inductance) and Litz wire (for low AC resistance) is particularly important for achieving the required resonant characteristics and high efficiency.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>What standards do TPS transformer windings comply with?<\/h3>\n<div>\n<div>TPS transformer windings are designed and manufactured to comply with relevant safety standards including IEC 62368-1, IEC 60601-1 (for medical applications), and UL\/CSA standards as required. Documentation packages support CE marking and regulatory compliance.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>What is the typical lead time for custom transformer winding?<\/h3>\n<div>\n<div>TPS provides quotes within 24\u201348 hours. Prototype quantities are typically available in 1\u20133 weeks, with series production timelines depending on material availability and test scope. DFM feedback is provided during the quotation phase to optimize design for manufacturability.<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/section>\n<footer style=\"background: #2d5797; padding: 30px; border-radius: 14px; margin-top: 40px;\">\n<p style=\"color: #ffffff; font-size: 16px; line-height: 1.6; margin: 0;\"><strong>Ready to manufacture high-frequency DC-DC converter transformers with low leakage inductance and Litz wire precision?<\/strong><br \/>Contact TPS Elektronik for engineering consultation, prototype evaluation, and production support\u2014from interleaved winding design to documented series manufacturing.<br \/><a style=\"color: #ffffff; font-weight: 600; text-decoration: underline;\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/winding-goods\/\">Request your transformer winding manufacturing quote \u2192<\/a><\/p>\n<\/footer><\/article>\n\n<style 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system integrators, electrical engineers, and procurement teams designing high-frequency DC-DC converters, the transformer is not a commodity. It is the component that determines conversion efficiency, EMI performance, and power density. A transformer with excessive leakage inductance wastes energy, generates heat, and radiates electromagnetic interference that can fail EMC testing. In resonant converters and soft-switching\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/how-to-achieve-low-leakage-inductance-and-high-frequency-performance-in-dc-dc-converter-transformers-with-tps-interleaved-and-litz-wire-winding-process\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":9,"featured_media":14612,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[58],"tags":[],"class_list":["post-16696","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How to Achieve Low Leakage Inductance and High Frequency Performance in DC-DC Converter Transformers with TPS Interleaved and Litz Wire Winding Process? - TPS<\/title>\n<meta name=\"description\" content=\"Transformer winding manufacturing process with interleaved and Litz wire techniques for low leakage inductance and high-frequency DC-DC converter performance.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/tps-elektronik.com\/en\/how-to-achieve-low-leakage-inductance-and-high-frequency-performance-in-dc-dc-converter-transformers-with-tps-interleaved-and-litz-wire-winding-process\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How to Achieve Low Leakage Inductance and High Frequency Performance in DC-DC Converter Transformers with TPS Interleaved and Litz Wire Winding Process? 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