Optimal Inductor Design Method for GaN-Based PFC

The main theme of this paper is to propose an optimal inductor design method for GaN-based PFC. The proposed method is developed based upon the minimization of PFC total losses, which include copper losses, core losses and switching losses of power devices. A systematic design flow chart is proposed to give the optimal turn number and stack number subject to the window area of core and minimization of PFC total losses. The proposed optimization design method is confirmed by analysis results first and then simulation results using ANSYS®. The designed optimized inductor is applied to a GaN-based 1.5 kW Totem-pole PFC for server power and the experimental results show the peak efficiency goes up to 97.5% and 99%, under 115V and 264V of input voltage, respectively. The results fully support the effectiveness of the proposed optimization design method.