Design of coils for high-power medium-frequency transformers using Grain-Oriented hot cores

This project shows how to design high‑power, medium‑frequency transformer (MFT) windings that are key parts of solid‑state transformer (SST) topologies. Because conventional Litz wire windings are expensive and hard to build, we explore using interleaved aluminum foil coils that are tuned to specific thicknesses. The electromagnetic performance and parasitic effects of this winding are studied with a multi‑domain approach. In practice, we create a two‑dimensional finite element method (2D FEM) model that links four separate sub‑models, each describing the local behavior of the foil coils. This model lets us calculate winding losses and leakage inductance accurately, ensuring the design meets high‑power SST requirements. We also evaluate the naturally high capacitance

between the interleaved foil layers and show that it helps keep the electric field uniform when fast‑front voltage pulses are applied. The work provides detailed simulation guidance, structural modeling, and performance‑evaluation frameworks for replacing costly Litz wire with inexpensive aluminum foil windings in medium‑frequency magnetic designs.

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