D15.3 - Exploiting the Depth: Design, Analysis, and Implementation of High-Power-Density High-Frequency Transformers for One Rack Unit CLLC DCX Converters

This paper focuses on the analysis and design of different transformer implementations for bi-directional DCX CLLC resonant dc-dc converters subject to a height and width constraint of one rack unit. Therefore, the depth of the high-frequency transformer must be exploited to increase the converter power rating. Different transformer configurations are analyzed in this paper, namely all-litz-wire, all-litz-PCB, and hybrid configurations. Designs are compared in terms of losses over the size, considering winding arrangement, proximity, and fringing effects, with emphasis on the cooling solution for increasing power density.