Design of a naturally cooled high frequency integrated magnetic component

A methodology for designing naturally cooled high frequency integrated magnetic component is presented. Windings losses are analytically estimated, and then improved using finite elements calculation. The component geometry determines the maximal temperature on the surface of component by taking account the natural air convection and radiation effects. During its thermal stability, a magnetic component (windings, core, and isolation) could have a homogenous temperature in all its parts because of the good thermal conductivity of copper and ferrites. A prototype of 500 W, 48V half bridge integrated current- doubler rectifier is implemented. Component temperature was simply detected using infrared camera. This methodology could easily be integrated in computer aided design tools recently developed for designing magnetic component.