Optimal constant-flux-inductor design for a 5 kW boost converter

The constant-flux concept is reviewed as a means to achieve high energy density and other electrical and thermal benefits by distributing the magnetic flux uniformly throughout the component volume. The paper investigates various methods to control the effective permeability of the cores, and the associated winding loss and core loss. The methods include winding layout, multiple permeabilities, Litz wire, and magnetic powder. For 50 μH, 19 A rms, 500 kHz, and 5 kW applications, the volume of the designed CFI is 50% of the commercial inductor with the same inductance while the total loss of the CFI is 43% of the commercial inductor.