Modified Power Factor Correction (PFC) Control and Printed Circuit Board (PCB) Design for High-Efficiency and High-Power Density On-Board Charger

Jaeil Baek, Moo-Hyun Park, Taewoo Kim and Han-Shin Youn
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Jaeil Baek: Department of Electrical Engineering, Princeton University, Princeton, NJ 08540, USA
Moo-Hyun Park: School of Electrical Engineering, KAIST, Daejeon 34141, Korea
Taewoo Kim: School of Electrical Engineering, KAIST, Daejeon 34141, Korea
Han-Shin Youn: Department of Electrical Engineering, Incheon National University, 119, Academy-ro, Yeonsu-gu, Incheon 406840, Korea

Energies, 2021, vol. 14, issue 3, 1-15

Abstract: This paper presents a modified power factor correction (PFC) ON/OFF control and three-dimensional (3D) printed circuit board (PCB) design for a high-efficiency and high-power density onboard charger (OBC). By alternately operating one of two boost modules of the PFC stage at a 50% or less load condition, the proposed PFC control can reduce the load-independent power loss of the PFC stage, such as core loss and capacitor charging loss of switches. It enables OBCs to have high efficiency across a wide output power range and better thermal performance. The 3D-PCB design decouples a trade-off relationship of the PCB trace design and heat spreader design, increasing the power density of OBCs. A 3.3 kW prototype composed of an interleaved totem-pole bridgeless boost PFC converter and full-bridge (FB) LLC converter has been built and tested to verify the proposed PFC control and 3D-PCB effectiveness design. The prototype has 95.7% full power efficiency (98.2% PFC stage efficiency) and 52 W/in 3 power density.

Keywords: electrical vehicle; interleaved PFC converter; onboard charger (OBC); totem-pole bridgeless boost converter; wide power range (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2021
References: View complete reference list from CitEc
Citations: View citations in EconPapers (4)

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