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An integrated inductor for a highly compact embedded battery charger is designed in this article. A zero-voltage switching (ZVS) buck converter is the selected topology to achieve high power density. ZVS is achieved by sizing the inductor based on energy balance and introducing the $k$ factor. A novel four-leg magnetic core structure is proposed as the integrated inductor. By introducing a modified parameter $\alpha _{\mathrm{eff}}$ to the improved generalized Steinmetz equation method, the optimal switching frequency for core losses can be found. From the constructed inductor model and semiconductor loss calculation, the design tradeoff and optimization is analyzed. The optimal $f_{\mathrm{sw}}$ is found to be around 2 MHz, which is when the performance factor for the core material peaks. As a proof of concept, a highly compact prototype, featuring stacked printed circuit board solution, with 16.2 × 19.2 × 6 mm $^{3}$ dimension is built. The input voltage ranges from 6 to 12 V, and the converter is capable of delivering up to 10 A at the 4-Voutput. Converter peak efficiency of 96% is achieved, and the inductor design has a power density of 113.6 W/cm $^{3}$. This shows improvement over several state-of-the-art designs. This article is accompanied by a video demonstrating the flux distribution in the magnetic core over the switching period. [ABSTRACT FROM AUTHOR]

This article investigates the gallium nitride based bridgeless dual single-ended primary inductor converter (SEPIC) power factor correction (PFC) with full input voltage range zero-voltage-switching (ZVS) turn-on for the application of step down ac–dc converter. The operation principle for the bridgeless Dual-SEPIC PFC and the theoretical analysis for the ZVS operation has been investigated. Furthermore, a new magnetic integration has been proposed to assemble all three inductors, including one input inductor and two output side inductors into one E-I-E core. The integrated inductor reduces the total ferrite volume and makes the converter more compact. The inductance design for ZVS SEPIC PFC and the magnetic reluctance modeling for the E-I-E core with the coupled inductor has been analyzed. The effective equivalent inductance of the input inductor can be implemented with a much less number of turns by a carefully designed coupling coefficient. Finally, a 300 W GaN-based MHz bridgeless dual-SEPIC PFC with the integrated inductors is developed and tested with full–range ZVS, 97% peak efficiency based on the ZVS extension strategy. [ABSTRACT FROM AUTHOR]

With the emerging technology of wide-band-gap power semiconductors and modern ferrite materials, the switching frequency of dc–dc converters can be pushed to mega-hertz range to achieve higher power density. In order to deal with a high conduction current, multiphase converters are adopted to distribute the current for both power devices and windings. However, the current unbalance among phases may cause unexpected power loss to the converters. In this letter, the current unbalance issue is addressed by an integrated current balancing transformer for a two-phase dc–dc converter. The current of two phases in the converter can be automatically compensated to be identical by the proposed structure, which also reduces the complexity of the control system. A 1-MHz GaN-based two-phase buck converter is built to verify the proposed structure and its efficiency achieves 97.5% at 4 V/6 A output with the ZVS turn-on of the switches. [ABSTRACT FROM AUTHOR]

This paper presents the circuit design and magnetic integration of push–pull class-E inverters for wireless power transfer (WPT) up to megahertz. The design criterion for achieving zero-voltage switching (ZVS) of a class-E inverter with coupled windings is derived mathematically. The approaches of magnetic integration for push–pull class-E inverters are analyzed and compared. Then, a new magnetic structure with hybrid magnetic materials is proposed to build the integrated inductors with either coupled windings or uncoupled windings. A 3-MHz WPT system is built to verify the analysis. The detailed comparison of the class-E inverters with magnetic integration is presented in terms of switch voltage, efficiency, harmonic currents, and thermal distribution. In the optimized design example, the switches keep ZVS over the entire load range without using any closed-loop control. The system efficiency reaches 87.1% at 350-W output power. [ABSTRACT FROM AUTHOR]

The integration of power inductors is a roadblock in realizing highly miniaturized power supply in package (PSiP) and power supply on chip. Inductors in such power systems are used for energy storage and filtering, but they dominate in size and loss. This paper presents a novel three-dimensional in-silicon through-silicon via (TSV) magnetic-core toroidal inductor for PSiP. The magnetic powder based core is embedded into a TSV air-core inductor using a casting method. The unique air-core inductor design with a hollow core and suspended windings enables a complete core filling with microscale magnetic powders. The proposed casting method is simple, scalable, and generic for a wide range of magnetic powders. TSV magnetic-core inductors are fabricated in a compact size of 2.4 mm × 2.4 mm × 0.28 mm with the core content varying from 63 to 88 wt% of soft ferrite NiZn powders. The TSV magnetic-core toroidal inductors are fabricated and electrically characterized. Small-signal measurements show a threefold higher inductance of 112 nH and a 30% higher quality factor of 14.3 at 12.5 MHz for magnetic-core inductors compared with similar TSV air-core inductors. The small-signal measurement results are verified by the modeled results. The total core loss is characterized by large-signal measurements. A suitable inductor is implemented in a 12-MHz buck converter that operates in a zero-voltage-switching mode. The converter achieves a peak efficiency of 71.6% and an output power of 2.4 W while converting 12 to 5 Vdc. [ABSTRACT FROM AUTHOR]

A highly efficient planar integrated magnetic (PIM) design approach for primary–parallel isolated boost converters is presented. All magnetic components in the converter, including two input inductors and two transformers with primary–parallel and secondary–series windings, are integrated into an E–I–E-core geometry, reducing the total ferrite volume and core loss. The transformer windings are symmetrically distributed into the outer legs of E-cores, and the inductor windings are wound on the center legs of E-cores with air gaps. Therefore, the inductor and the transformer can be operated independently. Due to the low-reluctance path provided by the shared I-core, the two input inductors can be integrated independently, and also, the two transformers can be partially coupled to each other. Detailed characteristics of the integrated structure have been studied in this paper. AC losses in the windings and the leakage inductance of the transformer are kept low by interleaving the primary and secondary turns of the transformers substantially. Because of the combination of inductors and transformers, the maximum output power capability of the fully integrated module needs to be investigated. Winding loss, core loss, and switching loss of MOSFETs are analyzed in-depth in this work as well. To verify the validity of the design approach, a 2-kW prototype converter with two primary power stages is implemented for fuel-cell-fed traction applications with 20–50-V input and 400-V output. An efficiency of 95.9% can be achieved during 1.5-kW nominal operating conditions. Experimental comparisons between the PIM module and three separated cases have illustrated that the PIM module has advantages of lower footprint and higher efficiencies. [ABSTRACT FROM PUBLISHER]