A High-Efficiency High-Density Wide-Bandgap Device-Based Bidirectional On-Board Charger

This paper proposes a novel two-stage topology for a 6.6-kW on-board charger. The first stage, employing an interleaved bridgeless totem-pole ac/dc in critical conduction mode to realize zero-voltage switching, is operated at over 300 kHz. A bidirectional CLLC resonant converter operating at 500 kHz is chosen for the second stage. A variable dc-link voltage is adopted to track the wide battery voltage range, so that the CLLC resonant converter can always operate at its most efficient point. The 1.2-kV SiC devices are adopted for the ac/dc stage and the primary side of dc/dc stage, while 650-V GaN devices are used for the secondary side of dc/dc stage. In addition, PCB winding coupled inductors and integrated transformer are implemented in ac/dc stage and dc/dc stage, respectively, for the purpose of high density and manufacture automation. The proposed structure is demonstrated to have 37-W/in3power density and above 96% efficiency over the entire battery voltage range, which far exceeds the current practice.