Optimization of Shielded PCB Air-Core Toroids for High-Efficiency DC-DC Converters

The paper describes the design of optimized printed circuit board (PCB) air-core toroids for high-frequency dc-dc converters with strict requirements in terms of volume and noise. The effect of several design parameters on the overall inductor volume, on dc and ac winding resistance, and on the radiated noise will be investigated. PCB toroids are compared to standard air-core solenoids and other state-of-the-art air-core toroids both theoretically and experimentally: at first, using ANSOFT Maxwell and ANSOFT Q3D simulation tools, and subsequently, with laboratory measurements (irradiated noise, efficiency, and frequency response) on several prototypes. These very flexible and rather easy to manufacture inductors appear very attractive for compact high-frequency dc-dc converters where high efficiency, low volume, and low noise are of primary concern.