Hello, everybody. I would like to design a transformer for a DC/DC converter. I would like to build the transformer as shown in the following link:
https://www.grupopremo.com/dcdc214-...-002-.html?search_query=transformer&results=8

The HV winding is to be realized with Litz wires and the high current LV winding with copper sheets. Does anyone know paper for the design of the windings, in relation to a low AC resistance. And how do I achieve the optimal interleaving.

 

I am not quite sure about the definition of the layers for the winding arrangement. The attached picture shows 2 different winding configurations. In the left picture I have 2 layers according to the literature and for this arrangement the AC resistance can be determined according to Dowell.

What about the sandwich winding shown in the right picture? Are the layers counted in the same way? So would I have 3 or 4 layers? Is it possible to use Dowell's formula to calculate the AC resistance for the sandwich winding?

 

I dislike discouraging ambitious intentions, but unless you have designed a transformer like this before, be prepared for plenty of failures along the way. The 55 euros you would pay for the finished product would probably be far less than you would pay for the materials to get started.

The interleaving is to minimize the leakage inductance. I think that to achieve optimum interleaving your should have the entire secondary within the primary. That is to say on the outside a primary layer, then a secondary layer...continue until all secondary layers have been placed, then one more primary layer on the outside.

 

Yeah, I know it's not gonna be easy. I have already considered the interleaving. Since I lay out the secondary side with copper sheets, I can only use the sandwich winding arrangement as shown on the right picture. (see previous post).

However, I have problems to calculate the AC resistance for the litz wires and the copper sheets and therefore to select the optimal thicknesses. I'm not sure if I can apply Dowell's formulas to the Sanwdich winding and if the number of layers will be counted differently.