Design process of high‐frequency inductor with multiple air‐gaps in the dimensional limitation

Abstract

To find the optimal magnetic components designing process within the dimensional limitation, different inductor arrangements are developed. Different combinations of air‐gaps and material arrangements are used within the limited bobbin space to improve the saturation current capacity within the already set dimension. In this study, the mechanism requirement set at 1 U height is the limitation. There are two center‐pole material cores, and air‐gap distribution arrangement in the magnetic components. The saturation current value, magnetic flux density, flux fringing, and power loss of inductors are investigated with simulation, equation calculation and actual circuit measurement. The magnetic distribution affects the inductor performance because of the different relative permeability values, skin effect, proximity effect, and fringing effect. This research uses equations to find the magnetic flux density and the fringing magnetic flux, and uses Comsol Multiphysics® software to simulate the magnetic field. A 500 W boost power factor corrections (PFC) converter topology is used as an example experiment to compare and verify the inductors selected with proposed design methodology. Finally, the most appropriate core is chosen to implement the two‐stage AC/DC power supply products to improve the power supply performance.