Flexible Multi-layer Foil Research Articles

Full Electromagnetic Integration of Impedance-Balanced EMI Filters for Single-Phase Power Converters

Utilizing passive electromagnetic interference (EMI) filters is the most widely used approach to restrain the conducted emissions from power converters. However, the introduction of these filters will significantly raise the weight and size of the systems. Using the emerging flexible multi-layer foil (FMLF) technique, this paper investigates a complete electromagnetically integrated design concept of single-phase EMI filters based on EE-type cores, which can be applicable to engineering application scenarios with different EMI noise attenuation requirements. Two types of integrated structures are constructed with different well-designed FMLF-windings and terminal configurations. One is a common-mode (CM) choke with controllable leakage inductances, which is able to realize the integration design of CM inductor, CM capacitors and differential-mode (DM) inductors. The other is an EMI choke with integrating the CM and DM inductances & capacitances, which achieves electromagnetic integration of all the CM and DM filtering components. Compared to the existing UU-type core based integration methods, the proposed methods can ameliorate the noise suppression performance while reducing filter's weight and volume. Theoretical analyses for modeling and design of the EMI chokes is presented. Then prototypes of different FMLFs based EMI filters have been built for a 500W 100kHz SiC-MOSFET inverter, experiments demonstrate the feasibility and validity of the proposed structures.

Modeling and Design of Full Electromagnetic Integration of a Symmetrical EMI Filtering Circuit With Flexible Multi-Layer Foil Technique

In a high-frequency power electronic converter with wide-bandgap device, electromagnetic interference (EMI) filter is an essential module for mitigating the conducted EMI issues. However, traditional discrete EMI filter will significantly increase total size and weight of the system. In this article, an UU-core based fully integrated symmetrical EMI filter is proposed using flexible multilayer foil technique, all the common-mode (CM) and differential-mode (DM) filtering components are integrated in the same unit for a more compact design. Moreover, a function-decoupling state is realized between the CM and DM elements, which contributes to predigesting the lumped equivalent CM and DM circuits. Then the parameter design procedure can be simplified. Prototypes of the proposed and other typical types of EMI filters are built for a 100 kHz SiC- <sc xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">mosfet</small> voltage source inverter, contrastive experiments have verified the feasibility and validity of the full electromagnetic integration approach.

Terminal Configuration Principles for Achieving Various Electromagnetic Integration Units with Flexible Multilayer Foil Technique

Terminal Configuration Principles for Achieving Various Electromagnetic Integration Units with Flexible Multilayer Foil Technique

A Fully Integrated Common-Mode Choke Design Embedded With Differential-Mode Capacitances

The emerging flexible multilayer foils (FMLFs)-based winding design has a great potential to promote the magnetic integration technique in power electronic systems. This article investigates the full integration of a single-phase electromagnetic interference (EMI) choke with well-designed FMLFs. By sharing a UU-type core and configuring the windings reasonably, all the common-mode (CM) inductance and capacitances and differential-mode (DM) inductances and capacitances can be integrated into the same core unit. Moreover, the proper terminal configuration of conductive layers can realize function-decoupling between CM and DM filtering elements, which contributes to simplifying the equivalent CM and DM models, then predigesting the parameters design procedure. Following the modeling and theoretical analysis, prototypes of the proposed and existing EMI chokes have been built for a single-phase 200-kHz SiC-<small>mosfet</small> inverter system. Through experimental measurements, performance comparisons have been presented to demonstrate the validity of this model.

A Review of Flexible Multilayer Foil Integration Technology for Passive Components

Passive integration technology is widely used in power electric converters since it can significantly reduce the volume of the passive components and improve the power density. This article highlights the flexible multilayer foil (FMLF) integration technology since it can meet the future requirements than other integration technologies. The realization, structures, and applications of the FMLF integration technology are summarized. The magnetic materials, dielectric materials, and conductive materials used in FMLF are investigated. Then, the approaches of the analysis and design for FMLF integrated units are introduced. Finally, it is compared with the planar printed circuit board integration technology to highlight the advantages of its characteristics and expounds its future research fields. Eventually, the power electronics engineers and researchers can comprehend the intrinsic properties of the FMLF integration technology.

Design of a Fully Integrated EMI Filter for a Single-Phase Grid-Connected Inverter

EMI filter is an essential part of the inverter system due to the high operative switching frequency of power switch tube. The optimization of electromagnetic interference (EMI) filter design has a far-reaching impact on the coming industrial application area. Based on the Silicon carbide (SiC) MOSFET single-phase inverter, this article investigates a full integration strategy with the UU-type ferrite core and flexible multi-layer foil (FMLF) applied. The FMLF contains electrical-, dielectric- and insulation layers. With the ingenious design of the FMLF windings, the inductance and capacitance can be integrated into the same unit. Based on the special design with double dielectric layer embedded, a novel full integration structure comes into being, with the common-mode (CM) and differential-mode (DM) capacitance designed following with the CM and DM inductance. The magnetic simulation has been conducted for analyzing the structure and ensuring that the core will not reach saturation under full load. A SiC MOSFET single-phase inverter has been designed as the experiment platform, and the conducted EMI noise measurement results have verified the feasibility and validity of the proposed fully integrated structure.

Passive Integration Using FMLF Technique for Integrated Boost Resonant Converters

As a high-efficiency converter for photovoltaic power generation, the integrated boost series resonant (IBSR) converter includes three inductors, two capacitors, and one transformer, which occupy a significant volume. In order to further increase the power density, this paper proposes a novel passive integrated unit with the flexible multilayer foil integration technique for the above six passive components. First of all, the distributed electromagnetic component model of one new flexible three-layer film shows that the distributed parasitic capacitors formed by the insulation film are combined into the resonant capacitance. Then, the configuration of the proposed integrated unit is described in detail, and the electromagnetic analysis is given. Furthermore, the design procedure for the proposed integrated unit is demonstrated. Finally, a prototype for a 350 W IBSR converter has been built and the experimental results prove the validity of the proposed idea.

An Optimization Design of Output Filter in a Grid Connected Inverter With Flexible Multilayer Foil Technique

Output filters of the grid inverter usually have a large footprint in the total system. In order to increase the power density of the grid inverter, a passive integrated structure for the output filter with flexible multilayer foils is presented. Compared with a discrete output filter, the volume of the integrated filter is reduced by at least 20%. In this paper, the design of the integrated output filter is discussed. Then, a distributed electromagnetic component model of the integrated filter is used to verify the proposed design. Finally, a prototype of the integrated output filter is built and used in a grid inverter. Experimental results are included and compared with the results derived from the discrete output filter to prove the validity of this integrated filter design .

Integration of Both EMI Filter and Boost Inductor for 1-kW PFC Converter

In order to increase the power density of the power factor correction converter, a novel integrated structure for both the electromagnetic interference (EMI) filter and the boost inductor is proposed with the flexible multilayer foil integration technique, which can reduce the volume of these passive components. Also, the performance of the proposed integrated structure is investigated based on the distributed electromagnetic component model. Furthermore, the design procedure for the integrated structure is detailed. Finally, a prototype of the integrated structure for both the EMI filter and the boost inductor has been built and the experiments demonstrate the validity of the integrated structure.

A PFC Converter With Novel Integration of Both the EMI Filter and Boost Inductor

In order to enhance the power density of power factor correction (PFC) converters, an integrated structure for both electromagnetic interference filter and boost inductors is presented with flexible multilayer foil integration technique. The electromagnetic analysis of the proposed structure is given, and the calculations of the circuit parameters are provided. A prototype of 1-kW PFC converter has been built. The experimental results are included to prove the validity of the proposed structure.

Design, Modeling, and Improvement of Integrated EMI Filter With Flexible Multilayer Foils

Integrated electromagnetic interference (EMI) filter design method with flexible multilayer (FML) foils is presented. An analysis model for integrated EMI filter with FML foils, distributed electromagnetic component (DEMC) model, is proposed. The DEMC model is verified by the experiment. In addition, method to improve the high-frequency performance of integrated EMI filter is investigated. Prototype of integrated EMI filter with FML foils is made for 1 kW switching power supply. In comparison with the traditional discrete EMI filter, it can reduce total volume by 45%.