Monolithic magnetic modules for aerospace power electronics applications

In order to address the need for planar magnetic components with reduced weight and volume that can operate at high frequencies and high power densities in high temperature environments, this paper describes the feasibility of monolithic magnetic technology for the development of reliable high performance electrical power components and systems for next generation aerospace and more electric aircraft power management and distribution equipment applications. Monolithic magnetic technology involves the integration of all the magnetic and electronic components of a power converter into a single monolithic non-magnetic module. The feasibility of the technology is demonstrated by integrating all magnetic components of a 100W, 1MHz DC-DC, two-transistor forward power converter into a 63.5mm x 63.5mm x 5.0mm single monolithic non-magnetic module using a single plasma-spray fabrication process.