Continuous improvement in integrated magnetics for innovative topologies for power converters

One of the key guiding parameters is the ratio between the resonant inductance and the magnetizing inductance. By applying these rules, we are now able to define the initial technological choices based on customer specifications. Simulation is then used only to fine-tune these design choices and to calculate critical values such as inductances and eddy current losses.

As of September 2025, Exxelia has successfully designed six CMIs. Among them, three have been tested and achieved immediate operational success, while two others are currently under fabrication or testing. These converters cover a power range from 1 to 25 kW and operate at frequencies between 100 and 320 kHz.

The targeted markets include aerospace, industrial applications, and space systems.

👉 For more information or to discuss your specific requirements, do not hesitate to contact our team.

Summary of the 2024 Article: Innovative Integrated Magnetic for DAB Power Converter

The original article introduced Exxelia’s first steps in developing integrated magnetics for Dual Active Bridge (DAB) converters. It highlighted the potential of merging multiple magnetic functions into a single component to achieve:

• Reduced volume and weight,

• Improved efficiency,

• Simplified assembly and integration,

• Better thermal management,

• Optimized electrical performance for high-frequency resonant converters.

The article also detailed how this innovation aimed to support next-generation aerospace, defense, and demanding industrial applications, where high power density and reliability are crucial.