The Challenges of Advanced Planar Magnetics for High Power Applications
While planar magnetics offer evolutionary benefits to high power and high density power conversion solutions, these benefits require additional focus to specific engineering and integration factors. At higher operating frequencies, ferrite material and core geometry selection and implementation are critical. Sourcing itself can be problematic given that the supply chains for high permeability materials are still growing and developing. Along these lines, high power densities equate to higher core flux densities as well. Avoiding core saturation while maintaining high densities can prove to be quite challenging. As with all technologies that seek to push physics to its edge, planar magnetics require tighter and tighter tolerance in design, assembly, and operation. With use cases such as Zero Voltage Switching (ZVS), poor tolerance bands can negate all topology benefits.
The SET Group Difference
Engineering and integration factors present new and complex challenges to any power conversion technology that seeks to leverage planar magnetics. This is why SET group has developed experience, tools, and even IP over the years.
- We have a deep understanding of electromagnetic components design. Our knowledge in RF and wireless power, has provided us with the tools to understand high frequency operation of magnetics (materials, designs).
- We use high-end software such as Maxwell and Ansys.to provide us with a deep understanding on how our magnetics designs interact at all levels of integration.
- We have developed proprietary tools to quickly develop high power magnetics, optimizing core material, geometry, construction, and cost to maximize power density.
- We have designed novel geometries and design architectures including coreless transformers, and additive-manufactured ferrite cores for novel power solutions.