Analytical Modeling and Implementation of a Coaxially Wound Transformer With Integrated Filter Inductance for Isolated Soft-Switching DC–DC Converters

In this paper, we propose an approach for integrating a series filter inductance in a coaxially wound transformer (CWT) as a potential alternative to conventional solenoidally wound transformers (SWT) for high-power isolated soft-switching dc-dc converters. The critical elements that determine the size and the performance of soft-switching dc-dc converters are the isolation transformer and the filter elements. While conventional SWTs using a stray magnetic field as a filter inductance often suffer from a considerably increased loss, heat congestion, and electromagnetic interference, a CWT is rarely affected by high frequency and fringing effects. The desired properties are still valid while the required filter inductance is fully integrated with an isolation transformer using the proposed method. In addition, the evenly distributed magnetic fields in a concentric geometry enable accurate electrical and mechanical analysis and a specific application-oriented design. In this paper, the operating principles, design procedure, and loss modeling of a CWT with an integrated filter inductance are introduced. Its functionality and suitability for high-frequency applications were proven by theoretical analysis and experiments. A prototype transformer with an integrated inductance 4 mH was facilitated and evaluated in a 15 kV-SiC mosfet-based 6 k-400 Vdc stage for a solid-state transformer of up to 6.5 kW at a switching frequency of 20 kHz.