Multiobjective Optimization of Ultraflat Magnetic Components With PCB-Integrated Core

• Published in: IEEE transactions on power electronics Vol. 28; no. 7; pp. 3591 - 3602
• Main Authors: Marxgut, C., Muhlethaler, J., Krismer, F., Kolar, J. W.
• Format: Journal Article
• Language: English
• Published: New York, NY IEEE 01.07.2013; Institute of Electrical and Electronics Engineers; The Institute of Electrical and Electronics Engineers, Inc. (IEEE)
• Subjects: Amorphous magnetic materials; Applied sciences; Circuit boards; Core loss; Design engineering; Direct current; Electric currents; Electric power; Electrical engineering. Electrical power engineering; Electronic equipment and fabrication. Passive components, printed wiring boards, connectics; Electronics; Exact sciences and technology; Flyback transformer; Magnetic devices; Optimization; Optoelectronic devices; PCB-integrated transformer; Perpendicular magnetic anisotropy; Power electronics, power supplies; power sheet; Power supply; printed circuit board (PCB)-integrated inductor; Printed circuit boards; Printed circuits; Semiconductor electronics. Microelectronics. Optoelectronics. Solid state devices; Toroidal magnetic fields; Transformer cores; Transformers; ultra-flat magnetics; High density; Lighting fitting; Multiobjective programming; Flyback transformer; Driver; Power supply; ultra-flat magnetics; Review; Inductor; Implementation; Power factor regulation; Organic electronics; PCB-integrated transformer; Direct current convertor; Flyback converter; Power factor correction; Printed circuit board; System design; Energy density; Power electronics; printed circuit board (PCB)-integrated inductor; Thickness; High energy; power sheet; Organic light emitting diodes; Magnetic core; Printed circuit; Flat screen; Magnetic device
• ISSN: 0885-8993; 1941-0107
• DOI: 10.1109/TPEL.2012.2226917

In future applications, e.g., in ultra-flat OLED lamp drivers or flat screen power supplies, ultra-flat ac/dc and dc/dc converter systems are highly demanded. Therefore, the design and implementation of a printed circuit board (PCB)-integrated flyback transformer for a 1-mm-thin single-phase power factor correction rectifier is under investigation. In this paper, first an overview on several integration methods is given. It is shown that the PCB integration of magnetic cores allows us to achieve the required thickness of 1 mm and a high energy density. In a next step, the design and the realization of ultra-flat magnetic components with PCB-integrated cores are discussed in detail. The presented multi-objective design procedure determines the inductor and/or transformer setup optimal with respect to minimal losses and/or minimal footprint area; for this purpose, all required electrical, magnetic, and geometrical parameters of the magnetic component are considered in the design process. Furthermore, all specific implications entailed by the PCB-integrated core, e.g., the core setup, anisotropic core losses, the interleaving of windings, or an accurate reluctance model are treated. Finally, experimental results are used to verify the design procedure.