Towards Lightweight Magnetic Components for Converters with Wide-bandgap Devices

Translating the higher switching speeds of new wide-bandgap devices into higher performance power conversion systems is often limited by the difficulties of realizing compact and low-loss magnetic components. This paper discusses some of the main technical challenges that limit magnetic component performance across a range of high-frequency converter applications including on-board DC-DC converters and wireless charging systems. Practical examples of innovative solutions to these challenges are presented, including core-less substrate- embedded resonant inductors for 13.56 MHz class-E inverters, high current (350 A) DC inductors with integrated thermal management, which demonstrate a 52% weight reduction, and a light-weight 400 Hz AC filter inductor with a 2.4 T core.