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Are there common metrics that usually degrade (ex. ramp time, line/load regulation, low-load efficiency) when pursuing more efficient designs, especially for isolated converters?

If you saw a new isolated high-power DC-DC converter advertising 99% efficiency, what performance factors would you be skeptical about?

(sorry if this is too broad again, still getting used to what scope I should write my questions at, and I have a lot of questions I'd like to ask.)

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    \$\begingroup\$ Cost. Cost is an important engineering design metric. \$\endgroup\$
    – The Photon
    Commented Sep 1, 2019 at 15:12
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    \$\begingroup\$ for EMI control, you need multi-layer PCBs; if the SwitchReg radiates, then 99% is doubtful; \$\endgroup\$ Commented Sep 1, 2019 at 16:13

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The high edge rates that high efficiency high frequency DC-DC converters usually require can potentially generate harmonic EMI/RFI across a vast range of EM spectrum (multiple HF shortwave bands and up), even if within legal (U.S. FCC, Part 15) RF limits. Good EMI/RFI filtering on the output and shielding of both the converter and the input feed cabling, both in design, and across component tolerances over a large production run can add to product cost. Mechanical stress, aging, and connection oxidation can allow an increase in any emitted EMI over time.

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  • \$\begingroup\$ The RF hash generated, by multiple solar panel, computer, USB, and LED lighting (etc.) switching voltage converters, can pretty much destroy shortwave (and amateur) radio reception over entire neighborhoods. \$\endgroup\$
    – hotpaw2
    Commented Sep 1, 2019 at 15:44

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