Fully bi-directional dc-dc converter for EV power train with power density of 40 kW/l

A converter design the main goal of which is reaching an ultra high efficiency and very high power density in the same time is discussed in this paper. The discussions concentrate on the power density aspects of the design and specifically on reaching high power densities by using solely conventional components. The paper demonstrates that careful spatial as well as thermal design can yield high power densities even without using special technologies. The results of the presented design are demonstrated on 60 kW, 50 kHz fully bi-directional dc-dc converter for application in an EV (electric vehicle) power train. The converter prototype exhibits power density as high as 40 kW/l and efficiencies in 99 % region in various operating modes.