Novel CCTT-core split-winding integrated magnetic for High-Power DC-DC converters

A novel CCTT-core split-winding integrated magnetic (IM) structure is presented in this paper. The IM device is optimized for use in high-power dc-dc converters. The IM structure uses a split-winding configuration which allows for the reduction of external leakage inductance, which is a problem for many IM designs. Magnetic poles are incorporated to help shape and contain the leakage flux within the core window. Low cost and low power loss ferrite is used which results in a very efficient design. An IM design algorithm is developed and implemented in Mathematica for design and optimization. FEA and experimental results from a 80 kW prototype validates the new IM concept and the CCTT magnetic was shown to be 99.7% efficient at full load.