Design considerations for transformers utilized in high-power high-frequency DC/DC converters are addressed. Major areas of concern are core-material selection, minimization of copper losses due to skin and proximity effects, and the realization of controlled leakage inductances. Coreless characteristics for various high-frequency materials are presented, and the influence of various conventional winding arrangements on the copper losses and leakage field is also demonstrated. Coaxial winding techniques (used commonly in high-frequency transformers) are investigated next as a feasible solution for containing the leakage flux within the interwinding space, thus preventing it from permeating the core and resulting in lower core losses and the avoidance of localized heating. Added benefits of this technique are reduced forces within the transformer, lower copper losses, and robust construction. The performances of two experimental single-phase 50 kW, 50 kHz units are reported. A three-phase version of coaxially wound transformers is also presented.
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