A design methodology for boost inductor applied to PFC converters considering the core temperature rise and the conducted EMI noise

This paper presents a design methodology to minimize the magnetic volume in a single-phase boost PFC converter operating in the continuous conduction mode (CCM) through the choice of the switching frequency and the input current ripple, taking into account the choice of magnetic material, the standard limits for conducted electromagnetic interference (EMI) noise generated, as well as ensuring single-layer winding and maximum temperature rise (losses) of the boost inductor. Some differences in the operation point that minimize the volume for the Sendust, Molypermalloy and High-Flux powder cores are discussed. The design methodology based on the models described in the paper is confirmed by experimental results obtained from a 650 W (400 V output voltage) universal line input (90-264 VRMS) PFC boost prototype, considering a switching frequency of 70 kHz and an input current ripple of 40%.