Dual Coupled Inductors With Controllable Integrated Leakage Inductance and CM Noise Suppression for CF-DAB Converter

A dual coupled inductors (DCI) structure is proposed, which integrates the two dc inductances, a high-frequency transformer and a leakage inductance into two standard EE cores. And the dc inductance and leakage inductance can be accurately controlled by designing the number of printed circuit board (PCB) windings and the air gap length. Consequently, a DCI dual active bridge converter is derived by the derivation process of the DCI structure. Furthermore, to suppress the CM noise, an improved PCB winding coupled inductor structure is proposed to reduce the parasitic capacitance. The proposed improved coupled inductor structure is obtained by the exchanged PCB layers and misaligned PCB windings. Finally, the validity of the proposed topology and design is verified by experimental results from a 1-kW laboratory prototype.