Integral design of 50 kW, 25 kHz dc-dc converter based on ZVS, Quasi-ZCS topology

Inhalt:
An improvement of power density is desired in many high-power applications. Reducing the size of passives is one of the cornerstones for realising high power densities. In this paper, an integral design of high-power highpower- density power converter is presented. The converter is based on ZVS Quasi-ZCS topology which is used to reduce the switching losses. Several concepts such as: foil winding technology, amorphous cores, leakage layer, heat removal by conduction and by heat pipes are discussed. The integral approach is demonstrated on a design of a 50 kW dc-dc converter prototype. The converter prototype demonstrates the possibility of achieving a high power density and a high efficiency at high power levels. In the presented case, an efficiency of 97 % is measured over a broad load range. The power density is as high as 11.13 kW/l.