A Novel Transformer Structure for High power, High Frequency converter

Power transformer structure is a key factor for the high power, high frequency converter performance which includes efficiency, thermal performance and power density. This paper proposes a novel transformer structure for the kilo-watt level, high frequency converter which is reinforce insulation needed for the secondary side to primary side. The transformer has spiral-wound primary layers using TIW (triple insulation wire) and PCB-winding secondary layers. All the windings are arranged by full interleaving structure to minimize the leakage inductance and eddy current loss. Further more, the secondary rectifiers and filter capacitors are mounted in PCB-winding secondary layers to further minimize the termination effect. A 1.2 KW (O/P: 12 V/100 A, I/P: 400 V) Mega Hz LLC converter prototype employed the proposed transformer structure is constructed, and over 96% efficiency achieved.