High Frequency Magnetic Sheet Materials Performance Factor Comparisons and Design of Toroidal Inductors Embedded in PCB

The integration of a high frequency (2-20 MHz) inductor device into the Printed Circuit Board (PCB) of a power converter would enable higher density integration of power converters [1] [2]. High frequency magnetic materials are required to reduce the size of an inductor device. This paper will consider commercially available thin flexible planar magnetic materials with a thickness of less than 500 mu m. These materials are shown capable of withstanding laser cutting into toroidal shapes. These magnetic cores are then used to create toroidal inductors which are electrically characterised in order to calculate the magnetic material properties. The standard performance factor [3] of the materials is used to make a comparison across frequencies. An embedded in-PCB toroidal inductor is fabricated with the thin flexible planar magnetic material. Finally, a thermal simulation of the embedded in-PCB inductor is shown and the power loss density limitations of the device are discussed.

Automated summary

This paper discusses the integration of high-frequency inductor devices into PCBs to achieve higher density integration of power converters, using commercially available thin flexible planar magnetic materials to manufacture toroidal inductors, and comparing magnetic material properties across frequencies through electrical performance testing.