Etd 59 smps transformer

[gedza]

I'm designing a high frequency transformer for a dc to dc 24v-311v inverter.Iwould like to ask if the ETD 59 3C94 would b esuitable using foil windings of thickness 0.04mm.Its rating is 1500va at 200khz

 

[Orson Cart]

An ETD-59 will easily handle 1500VA at 200kHz (keep the flux below 80mT unless you have cooling) the skin depth (of Cu) at 200kHz is roughly 0.14mm, the thickness of the foil is dictated by how many turns of foil you are using in any winding. 24Vrms requires only 1 turn at 200kHz/80mT so if you place HV windings either side of a full width single turn for the 24V then you can go to 0.1mm thickness for the single turn 24V wdg with quite low AC losses. You would need several of these 24V wdgs to get to the 63 amp rating you require, sandwiched between HV windings to keep the leakage down if required. Using 13 turns of foil for the 311V winding will give some additional AC losses if the foil is 0.04mm, plus the leakage will be high, for this construction with a low number of layers.
This sort of transformer design would tax a power electronics engineer even of 5 years experience (to get it near to correct the first time).

Hope this is of some help, Regards, Orson Cart