An optimal HF transformer design methodology intended for high-efficiency isolated ZVS DC/DC converters

One of the key elements for an adequate development of high performance isolated power converters is the proper design of High-Frequency (HF) transformers parameters. In practice, transformer designers have employed several techniques for achieve suitable designs, assuming rules of thumbs based on their expertise. In this paper, a design methodology for HF transformers based on product areas (Ap) that uses iterative processes in combination with rules of thumb for different specific variables, is presented and discussed. The most suitable design results for 100 kHz are implemented and validated to 1.5kW ZVS DC/DC Double-Half-Bridge converter (DHB). DHB is presented as an alternative for ZVS Full-Bridge converter counterpart [1]. HF transformer results present an estimated temperatures rise value of 19
^o
C, and an efficiency of 99.56%, coming out the overall converter efficiency close to 97% at rated power.