Resonant Cross-Commutated Dc-Dc Regulators with Omni-Coupled Inductors

The switching noise in a hard-switched point-of-load (POL) converter may result in false turn on, electromagnetic interference issues, or even device breakdown. A resonant cross-commutated buck (rccBuck) converter operates with low noise since all MOSFETs are turned on with zero voltage within a wide load range. A state-space model was developed to calculate the voltage gain, voltage stresses, and current stresses. Design guidelines for the rccBuck converter operating at continuous voltage mode or discontinuous voltage mode are provided. The design methodology of a one-turn inductor with significant ac and dc fluxes is given. Four fabricated one-turn inductors achieved 2.1% higher efficiency and 50% smaller total magnetic volume than the commercial inductors in the same rccBuck converter. The Omni-coupled inductors (OCI), composed of a twisted E-E core and PCB windings, further improve power density and efficiency. The core loss and inductances were modeled from a complex reluctance network. According to the loss-volume Pareto fronts, the total inductor loss was minimized within a smaller volume than that of discrete inductors. The expectations were validated by an OCI-based rccBuck converter switched at 2 MHz with 12 V input, 3.3 V at 20 A output, and peak efficiency of 96.2%. The small-signal model with a good accuracy up to half switching frequency was developed based on the averaged equivalent circuit. The transient performance of an rccBuck regulator is comparable to that of a second-order buck regulator with the same switching frequency, output capacitance, and closed-loop bandwidth.