Integrated Technology Of Flexible Multi-layer Foil For Electromagnetic Components And Its Applications

Switching power supplies widely used in information communication, industrial control, air transportation and other occasions. Power density is one of the key indexes for switching power supplies.From the perspective of improving power density, this paper points out that passive integrated technique is an important way to realize high power density of switching power supplies. This paper introduces the structures and the instancese of PCB (Printed Circuit Board) integrated technique and FMLF (Flexible Multi-Layer Foil) integrated technique. The materials, the advantages and the disadvantages of two integrated techniques are compared and summed up. The important theoretical value of DEMC (Distribute Electro-Magnetic Component) model for passive integration is presented as well.In this paper, the physical structures and equivalent models of three FMLFs are presented. The integrated structure I for both EMI filter and boost inductor in PFC converters is propoased with these three FMLFs. The electromagnetic analysis is illustrated as well. The DEMC modle is established, and the insertion loss performance of the integrated EMI filter is investigated. The design procedure of the integrated structure I is given. The experiment rusults on lkW PFC converter show the validity of the theoretical analyses.This paper presents a novel tolpogy which is reorganized from the typical PFC converter tolpogy. And the integrated structure II for EMI filter and boost inductors in novel tolpoly is proposed with two FMLFs. The electromagnetic analysis is introduced as well. Basd on the DEMC model of the integrated structure II, the CM (Common-mode) and DM (Differencial mode) EMI noises of the novel PFC converter are predicted. A prototype of lkW PFC converter is built, and the experiment rusults illustrate the validity of the theoretical analyses.The physical structure of an integrated transformer with two FMLFs for LLC converters is presented in this paper. The calculations of the resonant parameters are given and the design procedure of the integrated transformer is introduced. For lkW-lMHz LLC converter, three transformers with different types of dielectric film materials are built and tested. The performances of the LLC converter adopting different transforms are compared.