Due to the rapid adoption of the Electric Vehiclesworldwide, the On-Board/Off-Board Battery Chargers are facinga lot of challenges. One challenge is the charging time as the petroland diesel vehicles can be charged 10 times faster the electricvehicles. A second challenge is power density especially for the onboardcharger which required not to exploit a large space insidethe vehicles. Another challenge is the very wide battery voltagerange which makes it difficult to optimize converter over thewhole battery voltage range and efficiency drops either thebattery voltage is too high or too low. And finally the bi-directionaloperation, so that they can support the grid in the peak periods oreven standalone loads. In this paper, a 6.6kW two stage structureis proposed utilizing a variable DC-link voltage operation. Andone of the most promising challenge in the high-powerapplications is implementing the magnetics component intoPrinted Circuit Board (PCB). PCB winding transformer has beenwidely used in low power applications. Compared withconventional litz-wire transformer, the manufacture process isgreatly simplified and the parasitic is much easier to control.However, in high power applications, due to the limitation of highwinding loss and high multi-layer PCB cost, the transformerdesign with PCB winding becomes a challenge. The emergingwideband-gap devices provide the opportunity to adopt PCBtransformer in high power applications. In addition, the lowinductance requirement brought by high frequency also makes itpossible to realize magnetic integration in PCB transformer.
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