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High-Frequency Supplies
Parasitic elements are those electrical characteristics in the supply that
are not intended as the primary function of the components used within
the circuit but are nonetheless contributed by the physical construction
and layout of the components. Many of these parasitic elements within
the supply could be ignored in the PWM family of switching power
supplies when their frequency of operation is less than 50 kHz because
their overall effect on the power supply was minimal. At higher frequencies
of operation, these effects become much more significant in the role
they play in the efficiency of the power supply. Some are resistive in
nature, such as the ESR within the capacitors and the eddy-current and
hysteresis losses within the magnetic components. These dissipate real
(nonreactive) power, which contributes to the heat generated within the
supply. Some are capacitive in nature, that is, do not generate heat but
form an AC current path that bypasses the main power transformation
current path such as MOSFET gate capacitance and output capacitance.
Finally, there are those parasitic effects that are magnetically induced
that can couple into resistive losses such as skin effects in wires, and
those that degrade the performance of components within the circuit,
such as leakage inductance and interwinding capacitance. The effects of
all these parasitic elements are frequency-dependent and radically increase
as the frequency of operation increases. The losses contributed
by parasitic effects can, if not properly attended to, contribute as much
as 30 percent of the supplys total losses. Many can be reduced by the
proper selection of components; others can be harnessed and used inside
190 11 Resonant Converters-An Introduction
the power path, thus transforming a loss into usable energy. Within the
realm of resonant switching power supplies, the designer must possess
a practical appreciation of the parasitic effects to produce an efficient,
well-designed switching power supply.
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Several solutions can be used to reduce this effect. First is the use of
Litz wire. Litz wire is a woven bundle of small-diameter insulated
wires. This provides much more surface area, which promotes current
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1 1, Resonant Converters-An introduction
gap are bowed out away from the center of the gap in what is called the
frirtge effect. These lines of flux pass through the windings and induce
eddy currents to flow within them. This, of course, causes a resistivetype
loss within the windings, which results in still more heating of the
winding. This is where the trade-off in wire type and winding placement
comes into play. Eddy currents are more easily induced within conductors
that have larger cross-sectional dimensions. The foil windings have
a large surface area dimension, which gives them the greatest propensity
for the induction of eddy-current flow. Solid magnet wire has a fairly
large diameter dimension that also can permit the induction of eddy
currents within them. Litz wire offers the best resistance to the induction
of eddy currents because of the small diameter of each of these wires.
This is where three trade-offs should be considered: (1) dielectric isolation
between windings, (2) the degree of magnetic coupling needed by
each winding to the core and to the other windings to minimize leakage
inductance, and (3) which windings are better implemented using Litz
or foil wires. Ideally. a winding composed of Litz wire should be placed
adjacent to the core, followed by wires of ascending cross-sectional dimensions.
This goes contrary to the normal practice of interleaving
windings where half the primary is wound first, followed by the secondaries,
and then the remainder of the primary last. Dielectric isolation is
achieved by placing two layers of Mylar tape between the primary and
secondary windings. Unfortunately, the windings most needing the Litz
wire are the low-voltage, high-current secondaries. An additional layer
of Mylar tape is required to ensure the required dielectric isolation between
the primary and secondaries (see Fig. l l . 16). It also decreases
the magnetic coupling of the primary to the core, thus increasing its
leakage inductance. This can result in the introduction of spikes into the
primary's switching waveforms, thus requiring the addition of a clamp.
Alternatively, Litz wire could be used for the primary, but because of
its larger diameter and the fact that the primary usually requires the
largest number of turns, the core size may have to be increased as a
result. Obviously, not all the conditions can be satisfied, so some experimenting
with the winding arrangement may be necessary to minimize
the winding losses.