High power PCB-embedded inductors based on ferrite powder Rémy C AILLAUD 1 , 2 , Cyril B UTTAY 2 , Johan L E L ESLE 1 , 2 , Florent M OREL 2 , Roberto M RAD 1 , Nicolas D EGRENNE 1 , Stefan M OLLOV 1 , Céline C OMBETTES 3 1 Mitsubishi Electric Research Centre Europe, Rennes, France 2 Laboratoire Ampère, Lyon, France 3 3DPHI/LAPLACE, Toulouse, France 17/5/17 1 / 23
Outline Embedding of magnetics for power electronics Proposed Embedding Technique Results Conclusion MiNaPAD Forum 2017 2 / 23
Outline Embedding of magnetics for power electronics Proposed Embedding Technique Results Conclusion MiNaPAD Forum 2017 3 / 23
Passives for power electronics ◮ Main role: energy storage ◮ example: Q1 Q2 ◮ 1 kW converter @ 100 kHz L 1 I L 1 ◮ 10 mJ charge/discharge V L 1 per cycle V S C O V DC Load ➜ They are large ➜ Large impact on efficiency Q3 Q4 ✔ Embedding in PCB to save space MiNaPAD Forum 2017 4 / 23
Embedding of solid cores ◮ Machine a cavity in laminate ◮ Insert core in stack-up ✓ Use of high-performance materials M. Ali et al. , “Design of a hybrid integrated emc filter for a dc–dc power converter”, IEEE Trans. on PE, vol. 27, no. 11 [1] ✗ Few shapes available ✗ Machining difficult ✗ Brittle materials R. Perrin et al. , “2 MHz high-density integrated power supply for gate driver in high-temperature applications,” APEC 2016 [2] MiNaPAD Forum 2017 5 / 23
Embedding of laminated cores ◮ Thin magnetic layers ◮ Permalloy ◮ Amorphous material ✓ More compliant ✓ Easier to machine ✓ Suited to flat geometry ✗ Need to isolate layers ✗ Complex for high power C. Marxgut et al. , “Multiobjective optimization of ultraflat magnetic components with pcb-integrated core,” IEEE Trans PE, vol. 28, no. 7 [3] MiNaPAD Forum 2017 6 / 23
Embedding of flexible cores ◮ Ferrite/polymer mix ◮ “MagLam” Sheets ◮ Polyimide/ferrite paste ✓ Suited to flat geometry ✓ Suited to complex shapes E. Waffenschmidt et al. , “Design Method and Material Technologies for Passives in Printed Circuit Board Embedded Circuits,” IEEE Trans. on PE, vol. 20, no. 3 [4] ✓ Mechanically compliant ✗ Distributed air gap ◮ Low µ r values ( ≈ 10) D. H. Bang et al. , “Ni-Zn ferrite screen printed power inductors for compact dc-dc power converter applications,” IEEE Trans. on Mag. [5] MiNaPAD Forum 2017 7 / 23
Outline Embedding of magnetics for power electronics Proposed Embedding Technique Results Conclusion MiNaPAD Forum 2017 8 / 23
Embedding of ferrite powder in PCB ◮ Open cavities in a stack of pre-preg sheets ◮ fill cavities with ferrite powder ◮ laminate pre-preg to compact powder and infiltrate resin MiNaPAD Forum 2017 9 / 23
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