A Novel Magnetic Integrated Unit for A Full-Soft-Switching Full-Bridge Converter

Abstract

Full-soft-switching full-bridge converters have been widely used in various applications since they can improve the effectiveness of existing converters by reducing the switching loss. In this paper, a novel magnetic integrated unit is proposed with the flexible multi-layer foil (FMLF) integration technique to improve the power density of the full-soft-switching full-bridge converter, which integrates one series resonant inductor, one transformer and two coupled inductors into an E-E core geometry. Furthermore, the composition principle and design procedure of the proposed integrated unit are introduced in detailed, respectively. Finally, a simulation model based on Maxwell/Ansoft and a prototype of the integrated unit are built for a 500W-50kHz full-soft-switching full-bridge converter to testify the feasibility of the ideas proposed.