<p>With the development of electric vehicles (EVs), EV on-board power chargers are expected to pursue higher power density. Compared with active power devices, passive magnetics seem to be the main restriction for achieving higher efficiency and power density. The CLLC resonant converter is a common bidirectional isolation circuit topology used for the rear-stage DC/DC converter of the on-board charger, which requires multiple magnetic components. To reduce the number and volume of magnetic components and improve the power density of the CLLC converter, the two resonant inductors can be magnetically integrated with the transformer. This paper proposes a novel magnetic integration method that achieves asymmetric controllable leakage inductance through independent magnetic legs. Detailed integration methods and parameter design processes are presented. A 2000-W, 400-V to 300-V CLLC dc–dc converter is demonstrated to verify the effectiveness and feasibility of the proposed methods.</p>

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Optimization Design of Magnetic Integrated Planar Transformer for Bidirectional CLLC Resonant Converter

  • Fei Yang,
  • Zhipeng Lv,
  • Zhenhao Song,
  • Hao Li,
  • Zhihui Zhang,
  • Bin Dong

摘要

With the development of electric vehicles (EVs), EV on-board power chargers are expected to pursue higher power density. Compared with active power devices, passive magnetics seem to be the main restriction for achieving higher efficiency and power density. The CLLC resonant converter is a common bidirectional isolation circuit topology used for the rear-stage DC/DC converter of the on-board charger, which requires multiple magnetic components. To reduce the number and volume of magnetic components and improve the power density of the CLLC converter, the two resonant inductors can be magnetically integrated with the transformer. This paper proposes a novel magnetic integration method that achieves asymmetric controllable leakage inductance through independent magnetic legs. Detailed integration methods and parameter design processes are presented. A 2000-W, 400-V to 300-V CLLC dc–dc converter is demonstrated to verify the effectiveness and feasibility of the proposed methods.