The Design of a Contactless Unregulated Power Converter for the Separated Modules

In the contactless unregulated power converter application with high output current, optimizing coil structures and using synchronous rectification are important for achieving high efficiency. This paper proposes a separated planar structure of coils to achieve the design goals and gives its equivalent circuit model. On the power transmitting pad, double coils are used to enhance the ability of the output power levels. In order to implement full-wave synchronous rectification (FWSR), the power receiving pad also adopts double coils. The power coils on both sides have similar structures to obtain a balance-induced voltage in each half of the switching period, and the principles of the optimal turn ratio in coils are discussed. Meanwhile, four typical self-driven coil structures are compared and analyzed. The effect of the coupling coefficient and load currents on the loss of the duty cycle is discussed. To satisfy the requirements of output voltage, the rules for selecting the minimum ferrite core are summarized. A 120 W unregulated intermediate bus converter is built. The whole system achieves 90.7% efficiency under all loading ranges, and the maximum efficiency of the system is 94.5% at a 3.5A load current.