New magnetic integration of full-wave rectifier with center-tapped transformer

Full-wave rectifier with center-tapped transformer is a popular and competitive topology for power supply with high power density. Main transformer and output inductor are two large size components and have great roles on the power supply´s form factor. From the view of volume and height in a real product, a new integrated magnetic structure is proposed in this paper. The proposed structure has four core legs to get lower height and smaller size. The detailed flux operations in all core legs have been described in depth. Also, to reduce the DC resistance loss and improve winding connection in high output current application, an integrated secondary winding structure is proposed and formed with a whole punched copper plate. Finally, a prototype power supply operating with 130V~216V input, 14.5V/100A output, 90kHz switching frequency, is developed for verification based on the proposed new integrated magnetics.