The ongoing development in the area of lighting applications demands increasing power density (2W/cm3 as a goal) in power converters and a small and planar designs. Yet the functionality and the various specifications necessary to sell the products, such as wide output voltage range (30 V to 60V in the presented example), have to be fulfilled. In this paper the optimization process for a fully functional LLC resonant converter for LED lighting applications is described. A very small, integrated magnetic with low parasitic capacitance between the winding enables high frequency operation and still provides zero voltage switching over the entire range of operation, including a dimming range from 1% to 100 %. The presented design optimization introduces an optimal placement of the load independent point of operation and optimization parameters for an iterative design process. The design optimization is verified by simulation and measurements at a pre-series prototype1.
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