Improvement of Process for 25G Network Transformer
Time:2025-09-23
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The main improvement measures for the 25G network transformer in terms of process include improving the magnetic core material, optimizing the coil winding, and upgrading the packaging process, as follows:
Improvement of magnetic core material: Traditional network transformers often use nickel zinc ferrite magnetic cores with lower magnetic permeability. 25G network transformers often use materials with higher magnetic permeability, such as manganese zinc ferrite, whose magnetic permeability can reach three times or more that of nickel zinc ferrite. By winding the same inductance in this way, the number of turns required can be reduced by half, which helps to reduce the total length of copper wire, decrease distributed capacitance, and improve high-frequency performance.
Optimization of coil winding: On the one hand, double wire parallel winding, twisted wire and other methods are used to replace traditional single wire winding. If multiple enameled wires are twisted and wound together, it can increase the effective cross-sectional area of the copper wire, improve the high-frequency skin effect, and reduce signal transmission loss. On the other hand, by precisely controlling the winding length and number of turns, the balance of the coil is ensured. Multiple magnetic ring structures can also be used, stacking magnetic rings with high initial magnetic permeability to effectively reduce eddy current and hysteresis losses of the magnetic rings. At the same time, the copper wire winding length can be shortened while meeting the inductance requirements.
Packaging process upgrade: In order to meet the miniaturization and high-performance requirements of 25G network transformers, multi-layer ceramic substrates or chip level packaging technology are often used, which can achieve more compact designs, save PCB space, reduce overall costs, and improve the electrical performance and reliability of the product.
Manufacturing process optimization: Advanced automatic winding machines and precision packaging equipment are used to reduce manual intervention, improve production consistency and accuracy, help ensure product quality, and reduce defect rates.
Improvement of sealing process: During the sealing process, negative pressure and positive pressure equipment are used to first extract the air inside the sealing shell, so that the sealing glue presses the magnetic ring component tightly. Then, pressure is applied to the sealing glue to further release the internal air, making the inside of the sealing shell in a vacuum state, which can reduce the probability of bubble generation, improve product qualification rate and insulation effect.