Reaching high power density in multikilowatt DC-DC converters with galvanic isolation

Abstract

In this paper, the possibility of reaching high power densities in multikilowatt dc-dc converters with galvanic isolation is demonstrated and the main design issues are discussed. The issues related to converter topology, transformer design, and thermal management are addressed, and new conceptual solutions are proposed. Implementing zero-voltage-switching quasi-zero-current-switching topology, optimized transformer design with leakage layer, and thermal management based on conduction enhanced by heat pipes at critical places resulted in very high power density and efficiency. The power density reached by the converter prototype is 11.13 kW/L with water cooling and 6.6 kW/L with air cooling. In the same time, the measured efficiency exceeded 97% in a broad load range. The new design concepts are demonstrated on a 50-kW converter prototype that was successfully tested at full-load conditions.