A comparative design of an optmized boost inductor taking into account three magnetic materials technologies: Volume, cost and efficiency analysis

Reducing the volume with maximum efficiency, on equipment and systems, result in a high cost, making the optimized design a great challenge for engineers. On power factor correctors (PFCs) converters, magnetic elements as inductors and transformers have a strong influence on cost, volume, power density and performance, they become the more important elements in these systems. Thus, the need for an optimized design of these components is extremely important. With this purpose, this paper presents the inductor design for a 1kW, V_IN 220V_AC e V_OUT 400V_DC, PFC boost converter. The design is developed using different operating points (Δi @ fs) and different magnetic materials technologies (Molipermalloy, High Flux and KoolMμ) to perform a comparative analysis. These powder materials have extremely attractive characteristics for PFCs and this paper indicates which material offers the best cost / benefit relationship between the three technologies of magnetic materials aforementioned.