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A split-core technique is proposed to mitigate the gap losses in high-frequency nanocrystalline cores, which enables significant size reductions in thermally limited designs. Finite element analysis is used to examine the gap loss dependence on core width D revealing a nonlinear relationship of the form loss ∝ $D^{\alpha }$. α is approximately constant for frequencies of 10–200 kHz over the range of core widths typically used in power electronics, but α increases with gap length. Splitting the core into a number of subcores can therefore provide significant reductions in gap loss, especially with larger gap lengths. The results from a 300-A (peak), 200-A (continuous) inductor show that with three subcores and a gap length of 4 mm, the gap losses are reduced by 50%, and the hot-spot temperature is reduced by 24.5 °C. Using the technique it is estimated that the original inductor weight could be reduced by 40% with four split cores, making a significant impact on converter power density. [ABSTRACT FROM AUTHOR]

Finite element analysis is used to examine the gap losses that occur in finely laminated nanocrystalline inductor cores under high-frequency operation. The losses are seen to be concentrated in the region of the air gap and the dependence of the losses on key design parameters and operating conditions is explored. The results show that gap losses can be significant in this type of core, creating hot spots around the gap, and the losses are not accurately predicted by established design equations for low-frequency laminated cores. A modified loss equation is proposed. Validation is provided by measurements on a 300-A, 60 kHz inductor. [ABSTRACT FROM AUTHOR]