Concept of 50 kW DC/DC converter based on ZVS, quasi-ZCS topology and integrated thermal and electromagnetic design

A converter concept in the multi-kilowatt class with a high power density being the main goal is presented. High power density is achieved by implementing: ZVS, quasi-ZCS topology and integrated thermal and electromagnetic design. ZVS, quasi-ZCS topology reduces switching losses of IGBT switches and hence improves converter efficiency at high frequencies. Integrated thermal and electromagnetic design is used in high-power, high power density transformer which uses amorphous cores and foil winding technology together with heat pipes. A fully functional 50 kW DC/DC converter (750 V/600 V) and a virtual converter prototype demonstrate the possibilities of the converter concept. High power density (up to 13 kW/l without heatsink) and high efficiency (up to 97%) are achievable by using the proposed converter concept