Optimal design of a class of high frequency power inductors

A method for the design of inductors which exchange recurrently all of their energy in the order of Joules at frequencies of tens of kHz with the thereto associated network is presented. The constraint of the inductor's allowable surface temperature and the there with implied "hot spots" for an assumed type of specific geometrical configuration, governs a multiphase and concurrent search for the inductor's minimum physical weight, its minimum power loss, or a compromise thereof. The search is supported with the "mechanization" of magnetic component design by way of a computer program, which was developed for this purpose. The rate of heat removal from the component's surface is calculated in accordance with the prevailing conditions. The best suited permeability μ
r
results from the analysis of a specific inductor design for an assumed magnetic core material. A discrete or a "distributed" air gap can be prescribed. Test of fabricated inductors confirm the validity of the described method. The usefulness of the presented method is seen in the circumspection which is gained by a methodical and comprehensive analysis of a specific design requirement.