High-Frequency Power Transformers With Foil Windings: Maximum Interleaving and Optimal Design

Abstract

Foil conductors and primary and secondary interleaving are normally used to minimize winding losses in high-frequency (HF) transformers used for high-current power applications. However, winding interleaving complicates the transformer assembly, since taps are required to connect the winding sections, and also complicates the transformer design, since it introduces a new tradeoff between minimizing losses and reducing the construction difficulty. This paper presents a novel interleaving technique, named maximum interleaving , that makes it possible to minimize the winding losses as well as the construction difficulty. An analytical design methodology is also proposed in order to obtain free-cooled transformers with a high efficiency, low volume, and, therefore, a high power density. For the purpose of evaluating the advantages of the proposed maximum interleaving technique, the methodology is applied to design a transformer positioned in the 5 kW–50 kHz intermediate HF resonant stage of a commercial PV inverter. The proposed design achieves a transformer power density of 28 W/cm3 with an efficiency of 99.8%. Finally, a prototype of the maximum-interleaved transformer is assembled and validated satisfactorily through experimental tests.