Comparison of planar and Toroidal PCB integrated inductors for a multi-cellular 3.3 kW PFC
Résumé
The Printed-Circuit-Board (PCB) technology is attractive for power electronic systems as it offers a low manufacturing cost for mass production. In this paper, we present a procedure to design power inductors based on PCB. These inductors either use PCB for the winding only (Planar structure), or to host both the magnetic core and the winding (Toroidal PCB structure). The design procedure compares, in the form of a Pareto fronts, the two inductor structures over a large range of parameters (geometric parameters, magnetic materials), to identify the best candidates in terms of power losses and box volume. In this procedure, the core losses are taken into account using improved Generalized Steinmetz Equation (iGSE). The skin and proximity effects are considered using the AC resistance calculated with a FEM software. The inductor feasibility is checked from a mechanical perspective using the PCB design rules and from a thermal point of view with FEM simulation. A design case is presented for a 3.3 kW multi-cellular (3 interleaved cells) Power Factor Corrector (PFC). It is found that the planar design offers the most compact solution, but might present challenges regarding thermal management. The Toroidal PCB structure tends to be larger, but easier to cool.
Domaines
Electronique
Origine : Fichiers produits par l'(les) auteur(s)
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