OPTIMAL COUPLED INDUCTOR MAGNETIC CORE DESIGN FOR INTERLEAVED DC/DC POWER CONVERTERS

Interleaved DC/DC converters are widely used in high-power applications due to their ability to reduce current ripple, improve efficiency, and enhance transient response. The integration of coupled inductors further enhances performance by increasing ripple cancellation, reducing core losses, and minimizing inductor size, thus greatly increasing overall power density. This paper presents a design methodology for coupled inductors in interleaved converters using Finite Element Analysis (FEA) simulations and considering key design parameters such as mutual inductance, core material selection, core saturation and loss distribution. A comprehensive analysis is done in order to determine the optimal geometry, winding configuration, air gap placement and magnetic core size based on desired inductance and transient response. Analysis and design for the 4 kW inductor is performed using a coupled inductor simulation model using finite element analysis software. Simulation results validate analytical models and show significant improvements in comparion to conventional discrete inductors.