Design of high efficiency, low profile, low voltage converter with integrated magnetics

This paper presents an innovative design for a high efficiency, low profile, low voltage DC-DC power converter module intended for card mounted applications in a distributed aircraft power system. An innovative integrated magnetic structure for the half-bridge power converter lumps all the magnetic components into one structure and reduces the number of magnetic terminations. By incorporating advanced hybrid power packaging with the proposed integrated magnetic technique, a preliminary hybrid module of 1.6"/spl times/2.0" footprint and 0.21" height was developed. An overall efficiency (including the control circuit and power stage) of 90% was achieved for a 3.3 V, 100 W output operating at a 500 kHz switching frequency. The new integrated magnetic structure can be extended to other topologies.