Power packaging design considerations for high frequency high voltage generator

Power packaging technology plays an important role to achieve high performance for high voltage (HV) generator. The HV generator packaging techniques are systematically classified according to different component level packaging and system assembly technology. Both component level packaging and system assembly technology are included in the review and their advantages and disadvantages are discussed. Planar air-core multi-layer printed circuit board (PCB) winding transformer is introduced for HV generator with planar structure. A 450kHz switching frequency HV generator prototype with 310W output power and 1kV output voltage is built in lab. The high frequency HV generator prototype can achieve 1.09kW/L power density at rated 1kV output voltage and 310W full power. The litz wire air-core HV transformer prototype is built to compare the efficiency, thermal performance and size with planar air-core HV transformer. The planar PCB air-core transformer enables high voltage generation circuit system compact planar packaging. The litz wire air-core HV transformer behaves higher efficiency and thermal performance with low high frequency AC winding loss.