Optimization Design and Experimental Analysis of High-voltage High-frequency Transformer with Completely Resin Casting

Compared with traditional transformer, high-frequency transformer (HFT) exhibits good features such as high power density, small volume and weight, etc. This paper presents the application of an optimization design methodology which intended for HFT applications. First, a optimization design methodology is introduced, where the efficiency, volume, power density, leakage inductance and losses are taken into account. Then, in order to reduce the temperature of the HFT, a heat dissipation method is proposed. By adding a hollow pipe containing thermal conductive materials into the HFT internal structure, the hot spot temperature of core and secondary winding can be reduced effectively. Final, 10kHz/200kVA HFT prototype is built and the test results are reported.