Gapped Transformer Design Methodology and Implementation for LLC Resonant Converters

In the LLC resonant converter, the air gap is generally positioned in the core of the transformer for proper magnetizing inductance. Traditional transformer design methods assume infinite permeability of the core and no energy stored in the core. The improved design methodology for the gapped transformer is proposed with the optimum relative permeability and gap selection to meet the temperature rise and the magnetizing inductance requirements. The magnetizing current influences the magnetic flux in the core leading to the core saturation and core loss, while the resonant current contributes to the winding loss. The transformer design for a 200 W, 90 kHz LLC resonant converter is presented and experimental results validate the proposed methodology.