Heterogeneous Integration of EMI Filter Based on Flexible Multilayer Foils Technique

The newly developed flexible multilayer foils (FMLFs) winding design holds significant potential for advancing magnetic integration technology in power electronic systems. This article proposes the application of FMLF technology in the design of EMI filters. By utilizing a shared EE-type magnetic core and optimizing the winding configuration, all the common-mode (CM) inductors, capacitors, and differential-mode (DM) inductors and capacitors in the proposed EMI filter are integrated into a single core. Additionally, compared to the discrete filter and traditional heterogeneously integrated EMI filter, the EMI filter made with FMLF demonstrates superior performance, with significant advantages in size, weight, and efficiency, while offering noise suppression comparable to that of discrete filters. Based on modeling and theoretical analysis, an experimental prototype of the proposed EMI filter is built for a single-phase 500W SiC-MOSFET inverter. Performance comparisons are conducted through experimental measurements, which confirms the validity of the proposed model.