A High-Efficiency 80-kW Split Planar Transformer for Medium-Voltage Modular Power Conversion

A high-efficiency medium-frequency split planar transformer (MFSPT) based on low-cost ferrite core (PC40) is proposed for medium-voltage modular power conversion. By adopting a split planar structure, high electrical insulation is achieved with high efficiency, high power density, as well as excellent heat dissipation performance at the same time. A finite-element analysis simulation is carried out to investigate the distribution of the magnetic field and electric field in the MFSPT. The designed MFSPT prototype achieves a power density of 21.1 kW/L and electrical insulation of 42 kV. The performance of the proposed MFSPT is experimentally evaluated on an 80 kW, 43 kHz CLLC converter and the peak efficiency of the CLLC converter is 99.33%. This letter shows for the first time that high power, high power density, high efficiency, and high electrical insulation can be achieved simultaneously by using the split planar structure. This letter is accompanied by a supplementary file demonstrating the applied voltage insulation test.

Automated summary

This study proposes a high-efficiency medium-frequency split planar transformer based on a low-cost ferrite core. By adopting a split planar structure, the transformer achieves high electrical insulation, efficiency, power density, and excellent heat dissipation performance. Finite-element analysis and experimental evaluation demonstrate that this transformer can simultaneously achieve high power, efficiency, power density, and electrical insulation.