Integrated Inductor Design for a Highly Compact Embedded Battery Charger

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.