A High-Density 5kW 800V to 48VDC/DC Converter for Vehicle Applications

Xinyuan Du, Fei Diao, Yue Zhao, Kevin Uvodich, Nenad Miljkovic

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

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.

Original languageEnglish (US)
Title of host publication2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings
PublisherInstitute of Electrical and Electronics Engineers Inc.
Pages1502-1506
Number of pages5
ISBN (Electronic)9781728151359
DOIs
StatePublished - 2021
Externally publishedYes
Event13th IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Virtual, Online, Canada
Duration: Oct 10 2021Oct 14 2021

Publication series

Name2021 IEEE Energy Conversion Congress and Exposition, ECCE 2021 - Proceedings

Conference

Conference13th IEEE Energy Conversion Congress and Exposition, ECCE 2021
Country/TerritoryCanada
CityVirtual, Online
Period10/10/2110/14/21

Keywords

  • LLC resonant converter
  • additive manufactured cooling manifold
  • hybrid winding
  • magnetic integration

ASJC Scopus subject areas

  • Renewable Energy, Sustainability and the Environment
  • Energy Engineering and Power Technology
  • Electrical and Electronic Engineering

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