Optimal combination of insulation and thermal management for magnetic components

Host

Hitachi

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Client & task

Seven Games Company

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Objectives

In high-power and high-frequency magnetics, insulation systems must withstand elevated electric fields, rapid voltage transients, partial discharge activity, and high thermal stress. At the same time, the desire for compact magnetics (e.g., in solid-state transformers) places strict demands on thermal paths, requiring that insulation materials not impede heat extraction.
This creates a fundamental trade-off between dielectric robustness and thermal performance. Selecting the optimal insulation system—in terms of materials, impregnation strategies, geometry, thermal conductivity, and electrical withstand capability—is therefore pivotal to achieving high power densities while maintaining reliability and regulatory compliance.
This project systematically characterises insulation options, their thermal-electrical interactions, and their behaviour under representative converter conditions to derive validated guidelines for next-generation high-power magnetic components.

Objectives 1

Explore various insulation methods and materials (such as dry/air, resin impregnation) for high-power solid-state transformers, aiming to optimise power density while adhering to standards and considering thermal performance impacts.

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Expected Results

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19.7%
Identification of the optimal insulation approach for magnetic components in high-power environments, balancing power density with compliance to insulation standards and thermal efficiency/mitigation, supported by extensive measurements like partial discharge and breakdown tests.

Sed fringilla gravida lorem, id rhoncus justo egestas sed. Nulla sagittis vel ante sit amet neque non tellus interdum tincidunt eget eu odio. Awesome!

- Brian Green, CEO of Seven Games

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