This paper presents the design and analysis of a 22 kW SiC MOSFET-based bidirectional DCDC converter for on-board chargers (OBC) used in Electric Vehicles (EVs). Wolfspeed’s SiC MOSFETs (32 mΩ / 1200V) in TO-263-7 packages, along with an insulated metal substrate (IMS) PCB are used in the design. The bottom-side cooled power device offers lower parasitic inductances and facilitates automated assembly while IMS PCB exhibits superior thermal performance. A digitally controlled prototype with a switching frequency of 135 kHz - 250 kHz for a CLLC resonant converter was built and tested. The experimental results show that the design has achieved a power density of 9.4 kW/L and a peak efficiency of over 98.6% for a wide battery voltage range from 200V to 800V.
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Wang et al. (2024) studied this question.