Winding Scheme With Fractional Layer for Differential-Mode Toroidal Inductor

This paper studies how an outer fractional winding can impact the equivalent parallel capacitance (EPC) of a differential-mode inductor, which is a critical passive component in a power electronic converter to combat with electromagnetic noises, and proposes a winding scheme that can reduce EPC and increase inductance, achieving both high-frequency filtering performance and high density. To perform these studies, a comprehensive layer capacitance model based on energy equivalence principle is established, which decouples EPC contribution among three elements, i.e., outer fraction layer, layer-to-layer, and layer-to-core, thus enabling the impact evaluation of different winding elements and schemes. Experimental comparison results have validated the accuracy of this EPC model and excellent performance of the proposed winding scheme with EPC reduction by 4x. It reveals that contrary to previous understanding, the inverse winding, in fact, is more effective for EPC reduction than the direct winding in most of the partial layer scenarios, and that by using this scheme with the outer fraction layer, 45% higher inductance and slightly less EPC can be achieved, compared to the single-layer winding design.