Coupled PFC inductor for 22 kW on-board charger using PCB technology

The concept of the coupled inductor is adapted to operate in continuous current mode in a 22 kW on-board charger. In order to obtain a component with a very short thermal path, the two winding branches are each divided into two sub-windings. Besides the design, the focus is on uniform flux distribution in the four winding legs and the wiring of the sub-windings. The windings can be manufactured using PCB technology, making the component entirely machine-manufactured and therefore cost-effective. The designed PFC inductor is validated with measurement.