Development of a 100kW, 20 kHz Nanocrystalline Core Transformer for DC / DC Converter Applications

Achievement of high power levels in a single module inverter/converter application always has number of advantages. However, high frequency magnetic components most often become the limiting factor in the achievement of such high power levels in a single module. In this paper the achievement of 100kW in 20kHz transformer is discussed. This development is an extension of a series of developments carried out with high frequency, high power transformers of power and frequency levels such as 40kW, 20kHz and 50kW, 50kHz. The advantages and disadvantages of Ferrite and Nanocrystalline core materials at this power levels are discussed and the choice of Nanocrystalline core is explained. Further naval winding technique that mitigates high frequency conductor losses is presented in this paper with a theoretical explanation on its advantages.