Advanced Magnetic Components for High-Efficiency and High-Power-Density Converters

Introduction

Today’s magnetic components, such as inductors and transformers, in power converters operating at a low frequency of around 100-500 kHz are large compared to other electronic components. These components are a major constraint, limiting the miniaturization and integration of power electronic systems.

Challenges of Increasing Frequency

Increasing the switching frequency can reduce the size of the magnetic components, but this is generally accompanied by significant power losses. I aim to address the fundamental challenges of magnetic components in the frequency range of 1 MHz to 10 MHz. The main approach will be to reduce the power loss and the component size by creating unique and innovative solutions.

Objectives

My overall objective is to create novel magnetics technologies within conductor materials, nanogranular magnetic materials, and component integration. Together with a new winding pattern technique, this will enable the creation of power converters with unprecedented power efficiency and power density.

Specific Target

The specific target is to develop efficient, integrated magnetic components suitable for the voltage regulator modules (VRM) in high-performance computing systems. I will demonstrate a new VRM converter that is 50 times smaller in size and 5% more efficient than current VRM products. Achieving successful outcomes will have a major impact on the power electronics infrastructure, with the potential to reduce energy waste significantly.

Research Questions and Objectives

To do this, the project’s research questions and hypotheses will be addressed through 5 objectives in 5 corresponding work packages:

1. Mitigation of high-frequency eddy-current winding loss by creating a novel hybrid material structure;
2. Design of new magnetic materials with nanoparticles for a low magnetic core loss;
3. Creation of new core geometries and winding schemes in magnetics integration to handle large current efficiently;
4. “All-in-one” passive components integration mixing the functions of magnetics and capacitors;
5. Experimental verification and demonstration.