Design Proposal for xEV Magnetics General DC-DC Transformer Circuit

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This design proposal outlines specifications for a DC-DC transformer circuit for xEV applications, detailing input and output voltage ranges, current, switching frequency, inductance requirements, safety standards, mechanical dimensions, and loss comparisons. The proposal includes dielectric strength, turn ratios, leakage inductance, and heat dissipation estimates.

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Uploaded on Mar 04, 2025 | 0 Views

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Customer: TI Cyntec P/N: VT-19151B March 4, 2025 1

Design Form of xEV Magnetics General DC-DC Transformer (L2+L3) Circuit topology Input voltage range (V) Output voltage range (V) Output current (A) Switching frequency (kHz) Maximum duty cycle Primary inductance ( H) PSFB 200V-470V 9V-15V 300A (max) 100kHz 45% (due to control IC) (in the range of 500 uH 1mH) to be selected by Cytec To be Minimized, plus shim inductance (can be integrated with transformer housing but needs to have access to the inductor terminals) = 0.5uH Pri: Sec = 11 1 Leakage inductance ( H) Winding turn ratio Maximum temperature of transformer ( ) (self temperature rise included) Cooling conditions and maximum ambient temperature ( ) 100 including core temperature Air cool, 70 maximum ambient Primary to Secondary 5kV rms for 1 minute 2.5kV rms for 1 minute (assuming core is thermally coupled to heatsink and touchable) 500 Vac 6.1mm minimum 6.1mm minimum Meet 500Vac Hi-pot Dielectric strength / Hi-pot (Vac) Primary to Core Secondary to Core Primary to Secondary Primary to Core Secondary to Core Safety spacing requirement (clearance and creepage distance in mm) Safety standards (Recommended stds, like as UL 2202, UL 458A, IEC 60664-1 & IEC 60950-1 or others.) Specified lead wire & terminal (optional) Potting requirement (optional) Maximum available space (L x W x H in mm) Assembly method IEC 60664-1 design by cyntec design by cyntec design by cyntec, prefer lower height design by cyntec 2 CONFIDENTIAL AND PROPRIETARY Cyntec Confidential

Proposal Overview Dielectric Strength / Hi-pot (Vac): Lk Lp (1-2) @100kHz/1V ( H) L(1-2) DCR (m ) L(3-4) DCR (m ) @100kHz/1V (Sec. shorted) ( H) Turn Ratio Item PRI- SEC PRI- Core SEC- Core Customer s Request 500~1000 To be minimized 11:1 - - 5000 2500 500 9.7 Typ. 0.1 Typ. VT-19151B 500 Min. *1.9 TYP 11:1 5000 2500 500 Note : 100% check before shipment and don t care Cpk. PRI - SEC min. creepage/clearance: 6.1mm LResonant= Lk_trans+ Linductor = 1.9 + 3.1 = 5.0 uH 1 2 Schematic 4 Heatsink side 3 1 3 Np 11Ts Ns 1Ts Estimated Loss 2.96 W 3.92 W 7.26 W 2 4 PRI. SEC. Core Size: 94.5 * 65.7 * 42.0 mm3 Max. 3 CONFIDENTIAL AND PROPRIETARY Cyntec Confidential

Mechanical Drawing & Dimensions Front View Right View Bottom View 4 CONFIDENTIAL AND PROPRIETARY Cyntec Confidential

Dimensions & Loss Comparison Current Doubler Center Tapped Fig. Turn Ratio 11 1 21 1 1 65.7* 76.1* 50 mm (249988 mm3) 72.2* 84.4* 58.0 mm (353433 mm3) Volume PRI. 1.86 W 2.96 W SEC. 3.98 W 4.38 W Core 9.97 W 7.64 W Total Loss 15.81 W 14.98 W Estimated condition Vin:380 V / Vo:15 V 5 CONFIDENTIAL AND PROPRIETARY Cyntec Confidential

Dimensions & Loss Comparison Version A B Fig. Turn Ratio 11 1 11 1 76.1* 65.7* 50 mm (249988 mm3) 94.5* 65.7* 42.0 mm (353433 mm3) Volume Lk 4.4 uH 1.9 uH PRI. 1.86 W 2.96 W SEC. 3.98 W 3.92 W Core 9.97 W 7.26 W Total Loss 15.81 W 14.14 W Estimated condition Vin:380 V / Vo:15 V 6 CONFIDENTIAL AND PROPRIETARY Cyntec Confidential