Design and Demonstration of a 100 kW High-Frequency Matrix Core Transformer for More Electric Aircraft Power Distribution

The rapid development of more electric aircraft (MEA) raises the demand for high-power converters with significant weight and volume reduction for onboard power distribution. The isolated dc/dc converter using the medium-frequency transformer (MFT) is a feasible solution. To design an MFT with improved electromagnetic and thermal performance, a matrix core transformer (MCT) architecture is proposed with accurate models in this article. With superior heat dissipation ability, the high current windings can be effectively cooled with both natural and forced air convection. In addition, an optimization methodology for MCT design is presented. As a result, the prototype of a 100-kW, 50-kHz MCT with an additive manufactured bobbin is built. The results of both finite element analysis (FEA) simulation and experimental study in a full power dual active bridge (DAB) with the MCT prototype are presented to verify the theoretical design. The power density and efficiency of the MCT reach 17.7 kW/L and 99.63%, respectively.