Optimal Design Of High Power Planar Transformers And Inductors

With the rapid development of electronic technology, the switching power converter has been more and more attention. Higher efficiency, higher power density power supply products has become the object of each company to study. As an important part of the switching power supply products the affect the size, cost and performance switching power supply products directly, Which is one of the key elements in the switching power converter design. The appear of planar transformer provide a good direction for the optimization of the switching power converter. Therefore, planar transformers developed rapidly in recent years, however the design of high-voltage power planar transformer is more complex, Leading to the slow development of transformer, and high-power planar transformers can play a huge advantage in a number of power supply devices. Therefore, this article on the design of high-power planar transformer research to a planar transformer 20kW Case.First of all, this paper introduces the status of planar transformers and the purpose and significance of research high-power planar transformers Research. The structure type of planar transformers is introduced detailed, and the advantages and disadvantages of planar transformers to be described.Secondly, describes the thermal design of planar transformer, thermal design flow of planar transformer is given using simulation-based thermal design; Details of the planar transformer leakage inductance, distributed capacitance, core losses and winding losses and other parasitic will be introduced; And the impact to transformer leakage inductance and loss from planar transformer windings structure is analyzed based on electromagnetic simulation software; The optimization and simulation of planar transformer design will be given, Crossover winding structure will improve efficiency 20kW planar transformer to 99.3%, the power density of 30.7W/cm3; Calculate the temperature and thermal resistance in order to determine the reasonableness of the planar transformer design based on thermal simulation by Ansys Workbench.Then, a design applied to the LC series resonant converter in planar inductor, details of the impact of air-gap flux diffusion in inductor winding losses and optimization methods will be introduced,and put forward a novel core structure based on simulation, which can reduce 35.8% of the inductor winding losses.Finally, manufacture the high-power planar transformers has been designed, experiments show the accuracy of planar transformer design.