TY - GEN
T1 - A High-Density 5kW 800V to 48VDC/DC Converter for Vehicle Applications
AU - Du, Xinyuan
AU - Diao, Fei
AU - Zhao, Yue
AU - Uvodich, Kevin
AU - Miljkovic, Nenad
N1 - Funding Information:
This work was supported in part by the NSF Engineering Research Center (ERC) for Power Optimization of Electro Thermal Systems (POETS) with cooperative agreement EEC-1449548.
Publisher Copyright:
© 2021 IEEE.
PY - 2021
Y1 - 2021
N2 - In this paper, a high density 5 kW LLC resonant converter is proposed to enable a single stage dc to dc conversion from 800V to 48V for vehicle applications. The proposed LLC converter with hybrid winding structure features high efficiency and high power density. The primary winding is implemented by using vertically oriented copper foil embedded in a 3Dprinted bobbin to reduce the AC losses and the parasitic capacitance. The secondary winding, synchronous rectifiers (SR) and output capacitors are integrated in the same printed circuit board. In addition, a direct cooling approach using an additive manufactured (AM) manifold is proposed to further increase the power density of the converter. To validate the effectiveness of the proposed LLC design, a converter prototype has been developed with comprehensive experimental studies undergoing. Preliminary experimental results are presented in this digest. With the AM manifold, the prototype has achieved a power density over 5 kW/L.
AB - In this paper, a high density 5 kW LLC resonant converter is proposed to enable a single stage dc to dc conversion from 800V to 48V for vehicle applications. The proposed LLC converter with hybrid winding structure features high efficiency and high power density. The primary winding is implemented by using vertically oriented copper foil embedded in a 3Dprinted bobbin to reduce the AC losses and the parasitic capacitance. The secondary winding, synchronous rectifiers (SR) and output capacitors are integrated in the same printed circuit board. In addition, a direct cooling approach using an additive manufactured (AM) manifold is proposed to further increase the power density of the converter. To validate the effectiveness of the proposed LLC design, a converter prototype has been developed with comprehensive experimental studies undergoing. Preliminary experimental results are presented in this digest. With the AM manifold, the prototype has achieved a power density over 5 kW/L.
KW - LLC resonant converter
KW - additive manufactured cooling manifold
KW - hybrid winding
KW - magnetic integration
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U2 - 10.1109/ECCE47101.2021.9595198
DO - 10.1109/ECCE47101.2021.9595198
M3 - Conference contribution
AN - SCOPUS:85123362066
T3 - 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings
SP - 1502
EP - 1506
BT - 2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings
PB - Institute of Electrical and Electronics Engineers Inc.
T2 - 13th IEEE Energy Conversion Congress and Exposition, ECCE 2021
Y2 - 10 October 2021 through 14 October 2021
ER -