Study of a Topology of Low-Loss Magnetic Component for PCB-Embedding

A new process to manufacture low-cost PCB-embedded inductor-and transformer-windings is presented in details. Two prototypes are manufactured, one using a conventional technique and the other using our process. The prototypes have similar DC-resistances and inductances but the AC-resistance of the conventional one is up to 3.6 times higher than the other. Using the proposed design in a 28 V to 12 V-5 A buck chopper yields a 5-points increase of the efficiency. In the end, the proposed process is cost-effective and can be implemented on standard PCB manufacturing assembly-lines. It is barely more complicated than the common method, using PCB-tracks as windings, but results in much smaller losses.