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    Advanced Magnetic Materials and Geometries

    D22.1 - A New Low Profile, Power Dense Geometry for a 50 Kw Transformer with PCB Windings for Electric Aircraft Applications

    Thursday, March 26, 2026
    12:00 PM - 1:45 PM CT
    Location: Poster 11
    With the rapid development of electric aircraft, the demand for high-power and high-voltage converters has increased significantly. At the same time, the need for smaller and lighter magnetic components is becoming more critical. In response to these trends, this work focuses on the design and optimization of a novel transformer structure that offers several advantages, including the ability to adjust both leakage and magnetizing inductances, as well as self-capacitance. To prove this concept in a more realistic setting, the LLC power converter is used, as its use is widespread in aircraft due to its high efficiency, soft-switching capability and suitability for high-frequency, high-power applications. The proposed transformer design features enhanced heat dissipation capabilities, enabling more efficient thermal extraction compared to conventional transformers. To analyse this transformer, an analytical model incorporating three inductance modelling methods and a capacitive model was developed. A 50-kW prototype was built and validated through both simulations and experimental measurements, achieving a power density of 12.5 kW/kg.