Dual-use development of high density DC/DC converters

Rockwell Collins and Rockwell Science Center have teamed with the Office of Naval Research (ONR) to develop high density, high efficiency, programmable DC/DC power converters for both military and commercial applications. This three-year program aims at the development of two 100 W DC/DC converter modules that run off a 50 V DC bus and provide 3.3 V and 1.5 V outputs, respectively, at 90-95% efficiency, and with a power density at or higher than 100 W/in³. This paper provides an overview and a detailed analysis of the program goals and then discusses the technical challenges to achieve these goals. Key technology development efforts are also discussed. Up-to-date achievements in the areas of the evaluation and selection of power devices, circuit design and magnetics analysis are outlined