Analysis and Design of a High Power Density Flying-Capacitor Multilevel Boost Converter for High Step-Up Conversion

This paper explores the use of the flying-capacitor multilevel (FCML) topology in high step-up conversion. Compared to the conventional two-level boost converter, the FCML topology utilizes high energy density capacitors to facilitate inductors with storing and transferring energy during the conversion process, which brings features, such as lower voltage stress on the switches, reduced voltage stress on the inductor, and high effective switching frequency at the switching node. As a result, the total volume of the passive components in the converter is greatly reduced while maintaining high efficiency at high voltage gain. To demonstrate the potential high power density and high efficiency, a hardware prototype that converts 100 V to 1 kV with 820-W maximum output power is built. Such specifications require careful optimizations in many aspects of the converter to ensure a high power density and efficiency design. The implemented solutions and associate design process are presented in detail, with comparison with other state-of-the-art solutions. The hardware prototype has successfully demonstrated a peak efficiency of 94.1%, and 329 W/in3(20 W/cm3) overall power density.