High performance planar power transformer with high power density in MHz frequency region for next generation switch mode power supplies

The authors report the utilization of the core based transformer for power transfer applications with high power density and high energy efficiency in the MHz frequency region. A custom made POT core center tapped transformer of 4:1:1 turn's ratio using novel winding strategy with the core diameter of 16mm is designed and evaluated. The designed transformer has been characterized using sinusoidal excitation for a given output power in the frequency range of 1 - 10MHz and determined the operating frequency region of the transformer. The power tests of the transformer has been carried out up to the power level of 62W at an operating frequency of 6.78MHz with a peak energy efficiency of 98.5% resulting in the record power density of ~1100W/in³. The designed transformer has been characterized using class E isolated DC-DC converter topology at an output power of approximately 18W. The simulated energy efficiency of the converter is 88.5% under the full load condition. This work provides the significant step for the development of next generation high power density isolated converters (both AC/DC and DC/DC) in MHz frequency region.