A HF transformer design methodology for high efficiency isolated ZVS DC/DC converters

Proper design of High-Frequency (HF) and Low-Frequency (LF) transformers parameters is one of the key elements for a high-performance isolated converters design. In practice, transformer designers have employed several techniques for achieve suitable designs, assuming rules of thumbs based on their expertise. In this paper, a design methodology for HF transformers based on product areas (Ap) that uses iterative processes in combination with rules of thumb for different specific variables, is presented and discussed. The most suitable design results for 100 kHz are implemented and validated to 1.5kW ZVS DC/DC Full-Bridge converter. Results shown the temperature rise achieve the estimated value of 13.9 °C, and a HF transformer efficiency of 99.64%, in which it brings converter efficiency close to 97.50% at rated power.