Development of Forced Air-Cooled High-Frequency Transformer for Isolated DC-DC Converter

Wire-wound devices, such as AC reactors and transformers, account for a significant portion of dual-active-bridge (DAB) converters currently in use. The miniaturization of these wire-wound devices is crucial to achieving the miniaturization of equipment. In this study, we develop a forced air-cooled high-frequency transformer with a unique insulation cooling system. By integrating this transformer into a dual active bridge (DAB) converter, we achieve a compact and high-capacity system that delivers a rated output of 150kW in a volume of 75.6L, resulting in a power density of 2.0kW/L. This paper describes the design of the proposed transformer, which contributes to the miniaturization of DAB converters.