PCB Integration of a Magnetic Component dedicated to a Power Factor Corrector Converter

This paper focuses on the PCB integration of the magnetic component of a high switching frequency PFC converter (from 2 MHz to 8 MHz) constituted by a single-phase diode rectifier and a boost converter. In a first prototype the rectifier and the active components of the boost converter are reported on the top layer of the PCB. The maximum ripple current following in the inductance is 5 A (using self-oscillating current control) for a power of about 400 W. The paper describes the sizing of the inductance, the choice of the magnetic material and the technological process of integration. The implementation of these components into the PCB and the very high switching frequency allowed by the performances of the magnetic material and the GaN semi-conductor components make possible the design of a very high power density converter (about 10 kW/l).