11-kW High-Frequency High-Density Bidirectional OBC with PCB Winding Magnetic Design
Phu Hieu Pham, Ahmed Nabih, Shuo Wang, Qiang Li
Abstract
The trend of increasing power in on-board chargers (OBCs) is evident as demand of faster charging time from customers. This will lead to challenges for engineers to design the OBCs with high-performance, high-density, and cost competitiveness. In this paper, a SiC-based 11-kW two-stage bidirectional on-board charger system is introduced. With proposed motherboard-daughterboard concept, high frequency soft switching operation and PCB-based integrated magnetics, the proposed system architecture becomes more compact and more efficient compared to the state-of-art products on the market. The design consideration of the PCB-based magnetic components, including integrated coupled inductors and transformer, will be focused on this paper. The prototype of the 11-kW system is built which achieves up to 53 W/in <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sup> power density and above 98% efficiency of each stage over the wide range of the battery voltage.