A New Design of High-Frequency Magnetic Link With Hybrid Magnetic Core for Power Converter Applications

Advanced magnetic materials are extensively considered for the development of high-frequency magnetic links (HFMLs) for evolving power conversion applications. The conventional HFML designs incorporate a single permeability core and concentrated copper winding topologies. Consequently, the magnetic flux density in the core is unevenly distributed, leading to saturation in the core region close to the windings. In this paper, a new design of 1 kV, 40 kHz HFML is designed and analyzed for dc-dc power converter considering multi-permeability core and concentrated winding topology. The HFML core is designed with amorphous 2605SA1 and nanocrystalline F3CC125 magnetic materials. The electromagnetic performances and output power of the proposed HFML are analyzed and compared with the existing and proposed design considerations. The proposed HFML offers less core saturation more even magnetic flux distribution and around 5% higher output power at the secondary side load. The proposed core is developed in the laboratory with magnetic ribbon sheets of 2605SA1 and F3CC125. Finally, the proposed hybrid core-based HFML is successfully tested in the laboratory.