Design and Optimization of Laminated Metallic Cores for High-Frequency Transformers and Inductors Xuan Wang

Format:

Book

Thesis/Dissertation

Author/Creator:

Wang, Xuan, author.

Contributor:

University of Pennsylvania. Electrical and Systems Engineering., degree granting institution.

Language:

English

Subjects (All):

0215.

0544.

0607.

Local Subjects:

0215.

0544.

0607.

Physical Description:

1 electronic resource (123 pages)

Contained In:

Dissertations Abstracts International 87-07B

Place of Publication:

Ann Arbor : ProQuest Dissertations and Theses, 2025

Language Note:

English

Summary:

The growing demand for compact, high-performance power converters has driven the increasing use of high-frequency switching-mode topologies. This trend has introduced new performance requirements for magnetic devices, which are essential for energy storage, transfer, and isolation in such switching-mode converters. As switching frequencies increase to enable the use of smaller passive components, magnetic devices such as inductors and transformers based on conventional ferrite cores face inherent limitations in saturation, integration capability, and process compatibility. Fulfilling these emerging system requirements demands co-optimization of material properties, device geometry, and fabrication compatibility. This dissertation presents a system-oriented approach for developing laminated metallic (NiFe/PPy) magnetic devices through sequential multilayer electrodeposition to address the challenges of high-frequency, compact power delivery. The role of magnetic components in power converters can generally be classified into two types: energy-storage devices (inductors and coupled inductors), which prefer high saturation flux density to store and deliver energy efficiently without core saturation under high DC bias; and energy-transfer devices (transformers), which benefit from high permeability to ensure strong magnetic coupling and reduce leakage. The laminated NiFe material employed in this work simultaneously offers high saturation flux density and high permeability, while the fabrication approach provides geometric flexibility and compatibility with multiple integration platforms. To demonstrate practical applicability, laminated NiFe devices were developed across multiple scales and validated in diverse converter environments. At the microscale, TSV-integrated magnetic devices were realized by combining electrodeposition with silicon fabrication and demonstrated in a 13.15 MHz LLC converter. At the intermediate scale, PCB-embedded inductors were fabricated by integrating the process into standard PCB manufacturing and evaluated in a 4 MHz buck converter. At the millimeter scale, discrete magnetic devices formed through surface tension-driven assembly were demonstrated in flyback and LLC converters up to 3 MHz. Additionally, for applications requiring loose magnetic coupling, the laminated cores were applied in a 500 kHz wireless power transfer demonstration. Overall, these sequentially electrodeposited laminated NiFe devices demonstrate effective performance across diverse power delivery scenarios, supporting both energy-storing and energy-transferring magnetic functions, with potential for compact, high-frequency, and integration-compatible applications

Notes:

Advisors: Allen, Mark G. Committee members: Olsson, Troy; Gu, Lei

Source: Dissertations Abstracts International, Volume: 87-07, Section: B.

Ph.D. University of Pennsylvania 2025

Vendor supplied data

Local Notes:

School code: 0175

ISBN:

9798276006505

Access Restriction:

Restricted for use by site license