High-Efficiency High-Power-Density CLLC Resonant Converter with Low-Stray-Capacitance and Well-Heat-Dissipated Planar Transformer for EV On-Board Charger

Zhengda Zhang, Chunhui Liu, Mengzhi Wang, Yunpeng Si, Yifu Liu, Qin Lei

Research output: Contribution to journalArticlepeer-review

6 Scopus citations

Abstract

In this article, a high-efficiency high-power-density wide-bandgap-based CLLC resonant converter with a low-stray-capacitance and well-heat-dissipated planar transformer is presented, which is used as the isolated dc-dc stage for an electric vehicle on-board charger. A generalized planar transformer design methodology is proposed and validated by practical designs and experimental tests. A novel and simple transformer configuration is proposed to reduce the winding stray capacitance and enhance the winding thermal dissipation. The proposed transformer configuration is compared with different planar transformer designs, and the tradeoffs of employing the proposed design are well analyzed. Moreover, the system design and optimization of the high-efficiency high-power-density CLLC resonant converter is studied. The proposed transformer design and the system optimization approach are employed in a 6.6-kW/500-kHz CLLC resonant converter prototype. The prototype achieves a peak efficiency of 97.85% and a power density of 114 W/in^\text {3}.

Original languageEnglish (US)
Article number9034156
Pages (from-to)10831-10851
Number of pages21
JournalIEEE Transactions on Power Electronics
Volume35
Issue number10
DOIs
StatePublished - Oct 2020

Keywords

  • Electric vehicle (EV) on-board charger
  • high efficiency
  • high power density
  • planar transformers
  • resonant converters
  • thermal dissipation
  • wide-bandgap (WBG) devices
  • winding stray capacitance

ASJC Scopus subject areas

  • Electrical and Electronic Engineering

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