PSPICE simulations and 3D-PCB transformers for ZVS full bridge converters

This paper presents a compact 800 W ZVS full bridge power converter (500 kHz) designed by using advanced simulation techniques on PSPICE and an innovative low-leakage toroidal power transformer. The use of SPICE models for power MOSFETs and power diodes has made it easier to design the fixed-frequency, quasiresonant, phase shift, full bridge topology finally selected. This new and very compact power supply uses a combination of advanced circuit design and technological breakthroughs. The use of SMDs and multilayer ceramic capacitors reduces space and increases circuit reliability. The low-leakage toroidal transformer is realised by using a patented three-dimensional printed-circuit board technique which is revolutionary. The converter is currently in production