Minimum copper and core losses power inductor design

A design procedure which allows for assembling power inductors with minimum overall power loss is given in this paper. The inductor design is carried out by using an iterative procedure where the operating flux density is increased from zero to the saturation value. For any given value of the flux density the winding resulting in the lower AC resistance is determined. Both solid round wire and Litz wire windings are considered. The significance of the paper is that the design procedure allows for the combination of the flux density and winding which result in the lower power loss operation is determined. Therefore, inductors designed by following this procedure result in a high efficiency and minimum temperature rise.