diff --git a/asv_bench/benchmarks/pandas.py b/asv_bench/benchmarks/pandas.py
index 2a296ecc4d0..9bda5970a4c 100644
--- a/asv_bench/benchmarks/pandas.py
+++ b/asv_bench/benchmarks/pandas.py
@@ -29,19 +29,20 @@ def time_from_series(self, dtype, subset):
 class ToDataFrame:
     def setup(self, *args, **kwargs):
         xp = kwargs.get("xp", np)
+        nvars = kwargs.get("nvars", 1)
         random_kws = kwargs.get("random_kws", {})
         method = kwargs.get("method", "to_dataframe")
 
         dim1 = 10_000
         dim2 = 10_000
+
+        var = xr.Variable(
+            dims=("dim1", "dim2"), data=xp.random.random((dim1, dim2), **random_kws)
+        )
+        data_vars = {f"long_name_{v}": (("dim1", "dim2"), var) for v in range(nvars)}
+
         ds = xr.Dataset(
-            {
-                "x": xr.DataArray(
-                    data=xp.random.random((dim1, dim2), **random_kws),
-                    dims=["dim1", "dim2"],
-                    coords={"dim1": np.arange(0, dim1), "dim2": np.arange(0, dim2)},
-                )
-            }
+            data_vars, coords={"dim1": np.arange(0, dim1), "dim2": np.arange(0, dim2)}
         )
         self.to_frame = getattr(ds, method)
 
@@ -58,4 +59,6 @@ def setup(self, *args, **kwargs):
 
         import dask.array as da
 
-        super().setup(xp=da, random_kws=dict(chunks=5000), method="to_dask_dataframe")
+        super().setup(
+            xp=da, random_kws=dict(chunks=5000), method="to_dask_dataframe", nvars=500
+        )
diff --git a/xarray/core/dataset.py b/xarray/core/dataset.py
index d2ecd65ba58..433c724cc21 100644
--- a/xarray/core/dataset.py
+++ b/xarray/core/dataset.py
@@ -6465,7 +6465,10 @@ def to_dask_dataframe(
         columns.extend(k for k in self.coords if k not in self.dims)
         columns.extend(self.data_vars)
 
+        ds_chunks = self.chunks
+
         series_list = []
+        df_meta = pd.DataFrame()
         for name in columns:
             try:
                 var = self.variables[name]
@@ -6484,8 +6487,11 @@ def to_dask_dataframe(
             if not is_duck_dask_array(var._data):
                 var = var.chunk()
 
-            dask_array = var.set_dims(ordered_dims).chunk(self.chunks).data
-            series = dd.from_array(dask_array.reshape(-1), columns=[name])
+            # Broadcast then flatten the array:
+            var_new_dims = var.set_dims(ordered_dims).chunk(ds_chunks)
+            dask_array = var_new_dims._data.reshape(-1)
+
+            series = dd.from_dask_array(dask_array, columns=name, meta=df_meta)
             series_list.append(series)
 
         df = dd.concat(series_list, axis=1)