Modeling and Optimization of Integrated PCB CM Choke Structures with Improved DM Suppression using 3-D Electromagnetic Simulation

In this paper, an optimized design method of PCB integrated common-mode chokes (CMCs) for electromagnetic interferences filters is presented. These CMCs are integrated with custom-shaped ferrite plate cores O, UI, and EI to help realize various low-profile devices. The design of the PCB CMC is based on a dedicated optimization algorithm implemented to characterize compact CMCs with effective common-mode (CM) and differential-mode (DM) inductances taking into account their structures' geometric parameters and saturation issues of their magnetic plate cores. The algorithm suggests a variety of optimal CMCs configurations using a low computational task. 3D finite element method simulations and analytical modeling of the optimized PCB CMCs are conducted to assess their electromagnetic performances and characterize their high-frequency behavior. The proposed optimization method greatly improves the size compactness of integrated PCB CMCs while effectively controlling the CM and DM saturation levels of their magnetic plate cores. It also enhances the filter's effectiveness in DM while ensuring CM filtering performance comparable to filters with traditional CMCs.