Rethinking Power Delivery with Solid-State Transformer Technology

🔹 Background Information

Conventional medium-voltage transformers operate at low frequencies (50–60 Hz), requiring large silicon-steel cores, numerous aluminum windings, and heavy-duty enclosures to support their considerable weight. As a result, they are bulky, heavy, and suffer from lower efficiencies due to core and conductor losses. Their significant weight also necessitates reinforced mounting pads in applications exceeding a few hundred kilowatts, further increasing real estate demands and installation costs. Manufacturing these traditional units requires specialized machinery and facilities—resources that are limited globally—leading to typical lead times of up to 18 months.

In modern applications such as EV charging, aerospace electrification, renewable energy, grid-scale storage, and data centers, conventional transformers are often paired with downstream power converters for AC/DC conversion. These converters handle the full output power—ranging from 200 V in smaller data centers to 1,500 V in solar installations—resulting in additional magnetic material, higher converter costs, and increased logistical complexity.

To address these challenges, traditional transformers and low-voltage converters can be unified into a single-stage power conversion system known as a Solid-State Transformer (SST). This approach uses a medium-voltage multi-level inverter to interface the medium-voltage grid and produce an intermediate high-frequency AC signal (typically 20–50 kHz), which is then processed through compact, high-frequency isolation transformers to deliver the required DC or AC output at the desired voltage level. By eliminating redundant stages, this architecture dramatically reduces magnetic volume, improves efficiency, and streamlines installation.

While SSTs have been studied for years, the recent commercialization of cost-effective Silicon-Carbide (SiC) semiconductor devices has made them a viable and competitive alternative to traditional transformer-converter solutions. A growing number of companies are now pursuing SSTs for use in industrial, transportation, energy, and data center sectors.

At Infinity Flow, we are redefining this landscape with a proprietary SST architecture designed from the ground up for performance and scalability. Leveraging advanced SiC devices, a patent-pending topology, intelligent control systems, and a rigorous design methodology, our solution achieves industry-leading efficiency, reliability, and compactness.

“Our new high-frequency transformer is a critical step toward the future of scalable and modular medium-voltage power delivery.”

— Infinity Miles Engineering Team

 

 

🔹 Why do we need “High Frequency” isolation?

Increasing the switching frequency enables the use of significantly smaller magnetic components, as the required magnetic volume and weight are inversely proportional to operating frequency. With the availability of advanced magnetic materials and the emergence of low-cost, high-performance Silicon Carbide (SiC) switches, it is now feasible to design and build medium-voltage converters that operate reliably at tens of kilohertz. This advancement marks a key enabler for compact, efficient power conversion systems.

Benefits of high-frequency SSTs include:

• 📉 75%+ weight reduction compared to traditional units
• 📦 65%+ smaller footprint, easing integration into EV charging, renewables, and mobile grid systems
• 💡 3–5% increase in efficiency, thanks to reduced core losses and better thermal behavior
• 💰 Lower capital cost, driven by smaller component size and modularity

 

🔹 Our Breakthrough: 50kW Prototype

We are proud to announce that Infinity Miles has successfully designed, built, and tested a fully functional 50 kW high-frequency transformer/converter module. This achievement represents a critical proof of concept and a foundational step toward the development of our 1.5 MW solid-state transformer platform.

🚧 Key Features:

• Power level: 50 kW (scalable to 1.5 MW)
• Switching frequency: 40–50 kHz
• Topology: Multi-level SiC-based bidirectional converters
• Isolation: High-voltage insulation and encapsulation

 

Caption: a 50 kW High-Frequency Transformer built and tested in-house at Infinity Miles

 

🔹 Testing & Validation

Our internal testing validated the design’s performance in:

• ✅ Magnetic performance at high frequency
• ✅ Thermal stability under sustained load
• ✅ Electrical isolation and safety standards compliance

The transformer has passed bench testing with input voltages scaled for medium-voltage simulation, verifying performance metrics needed for EV charging, solar farm integration, and distributed grid systems.

 

🔹 Application

Our SSTs are ideal for applications including but not limited to:

• EV fast charging stations
• Utility-scale solar and wind energy integration
• Microgrid and energy storage systems
• High-power industrial energy systems
• Data Centers

 

🔹 What is Next

We are scaling this design toward a 1.5 MW modular SST unit for real-world deployment and field testing. We are also engaging with strategic partners and early adopters to pilot this system across electric vehicles and e-VTOLs, renewable energy, data center, and grid modernization use cases.

 

🔹 About Infinity Flow

Infinity Miles Inc, DBA Infinity Flow is building the future of electrification through modular, solid-state-based power conversion technology. Our mission is to decarbonize and decentralize energy distribution by replacing aging infrastructure with efficient, intelligent systems.