Finite-element analysis of copper loss in 1-10 MHz transformers

Issues related to the copper loss in the planar windings of 1-1 MHz power transformers are discussed. The relationship between current distribution, copper loss, and core geometry is investigated with the aid of finite-element analysis. Magnetizing current proximity effects are shown to cause excessive copper loss in a simple sandwich transformer, a structure formed by sandwiching the planar winding between two plates of magnetic material. Three alternative transformer structures that reduce this problem are compared. These alternative structures are: the cofired transformer, the slotted gapped transformer, and the slotted ungapped transformer. It is concluded that a slotted transformer design should be used if the magnetizing current is relatively large. Both a slotted gapped and a slotted ungapped design relies strongly on the exact permeability of the material and may suffer from higher core losses because all of the energy is stored in the magnetic material, rather than in an air gap. In either case, the depth of the slot should be About 40% of its width