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

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.