Fully integrated planar magnetics for primary-parallel isolated boost converter

A high efficient planar integrated magnetics (PIM) design approach for primary parallel isolated boost converters is presented. All magnetic components in the converter including two input inductors and two transformers with primary-parallel and secondary-series windings are integrated into an E-I-E core geometry. Due to a low reluctance path provided by the shared I-core, the two transformers as well as the two input inductors can be integrated independently, reducing the total ferrite volume and core loss. AC losses in the windings and the leakage inductance of the transformer are kept low by interleaving the primary and secondary turns of the transformers. To verify the validity of the design approach, a 1-kW prototype converter with two primary power stages is implemented for a fuel cell fed battery charger application with 20-40 V input and 170-230 V output. An efficiency of 96% can be achieved during nominal operating conditions. Also experimental comparisons between the PIM module and two separate cases have been done in order to illustrate the advantages of the proposed method.