Layout Design of 1.2kV, 11kW, 100kHz Matrix Bridge Leg for Single- Stage Three-phase AC to DC Dual Active Bridge based converter

Abstract:
The single-stage AC–DC isolated converter is an emerging area in power electronics with applications in onboard/offboard EV chargers, hydrogen generation systems, large-scale grid energy storage, etc. Compared to conventional two-stage converters, the single-stage approach offers higher power density, improved efficiency, and enhanced reliability. Among these, single-stage three-phase AC–DC matrix converters are gaining attention for high-power applications. A typical three-phase AC to single-phase AC matrix converter has two high-frequency switching nodes, each connected to three input phases through four-quadrant switches. However, these switches create multiple commutation loops, where bad PCB design leads to issues such as voltage overshoot, ringing during turn-off, and current overshoot during turn-on. To address these challenges, this paper proposes a new matrix converter layout that mitigates switching transients. The design introduces a four-layer PCB structure with individual highfrequency decoupling capacitors and damping resistors for each commutation loop, thereby minimising parasitic loop inductance. Experimental validation confirms the proposed layout effectively suppresses switching transients and enhances overall converter performance.