Abstract:
High-power-density, high-efficiency power converters are still gaining popularity. High-frequency operation reduces power converter size, but magnetic components limit it. Widebandgap devices raise power converter switching frequencies to hundreds of kilohertz, enabling PCB winding planar magnetics. Planar magnetics reduce converter size and improve reliability through automated manufacturing with repeatable parasitics compared to litz-wire-based magnetics. Magnetic integration reduces power converter size and magnetic components. This paper proposes a PCB winding-based magnetic structure that combines inductor and transformer. By changing the core cross-sectional area or air gap length, this structure allows easy inductor value control. The proposed PCB winding-based magnetic structure is tested with a 6.6-kW 500-kHz CLLC resonant converter prototype with 98% efficiency and 130-W/in 3 (8 kW/L) power density.
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