Active buffering increases the power density of on-board chargers for electric vehicles. An active power filter (APF) is used to provide a stiff DC voltage to charge the battery. This DC voltage is obtained from a single-phase AC grid using a front-end power factor correction circuit (PFC). To enhance the quality of grid current, interleaving is used. This paper integrates a half-bridge APF with an interleaved totem-pole PFC. Leg sharing between PFC and APF can further reduce the number of components. However, it increases component stress and reduces the degree of freedom of the circuit. As a result, the current flow deviates from its intended path. In shared structure, the line current mimics the PFC operation but fails to follow the exact PFC profile. This becomes prominent in the case of interleaving. This phenomenon is explored for the first time and termed as “Restricted Interleaving Phenomenon”(RIP), which leads to increased input current ripple and affects the APF operation. This disturbance can be controlled by operating the circuit at a higher output voltage and increasing the APF switching frequency. Experimentally phenomenon is observed and analyzed in the proposed shared structure, followed by its control and impact on specific topologies.

Restricted interleaving phenomenon in Interleaved Boost PFC with leg sharing APF circuit

This paper proposed a design method for a toroidal transformer intended for LLC converters, whose leakage and magnetizing inductances can be designed independently. In the proposed transformer, the primary leakage inductance can be adjusted by varying the height of spacer between the primary and secondary winding, while the magnetizing inductance and secondary leakage inductance are constant. The error rate between the estimated primary leakage inductance derived from the approximation straight line and the actual primary leakage inductance of the prototype is 0.5%.

Design Method of Leakage Inductance of MHz Toroidal Transformer for LLC Converters

This paper focuses on how to perform zero-voltage-switching (ZVS) control in GaN-based interleaved critical conduction mode (CRM) totem-pole power factor correction (PFC) rectifier with adaptive ZVS control. An improved variable-step adaptive control method is proposed to minimize control errors. Compared to methods with zero-current detection (ZCD), the adaptive ZVS method does not need current sampling. The status of ZVS can be measured by reverse conduction voltage comparison, and the synchronous rectifier (SR) on-time is tuned in control cycles. The control system is implemented in a microcontroller, and a 1.5kW GaN-based interleaved PFC prototype is built with a peak efficiency of 98.9%.

GaN-based Interleaved CRM Totem-pole PFC Rectifier with Variable-step Adaptive ZVS Control

In recent years, the power supply of the data center is increasing day by day. The new power supply architecture uses 48V bus to supply power to the subsequent VRM, so as to reduce I2R loss. Because of its soft switching characteristics, LLC resonant converter can meet the requirements of high power density and high efficiency, and is used in isolated DC-DC converter. In this paper, a magnetic integrated transformer is proposed to reduce winding loss and core loss. The windings and magnetic cores are optimized in local detail. A 1500W module was made in the experiment, achieving 97.8% peak efficiency and 97.6% efficiency at full load. 

1.5kW LLC Resonant Converter with improved interleaved winding structure and core structure

Reverse coupled inductor has high integration and low loss, but the control method of PFC is difficult. Uncoupled inductor retains the high integration of reverse coupling, with small loss, simple design and simple control mode. This paper proposed a method of S-shaped coil, four column structure for interleaved parallel PFC uncoupled inductor. Simultaneously, the experimental prototype for 1500W/400V output with two-phase interleaved PFC is designed. The peak efficiency is up to 98.75% and the full load efficiency is 98.4%.

S-shaped coil, Four Column Design Based On Interleaved Parallel PFC Uncoupled Inductor

High-frequency resonant converters with PCB-based transformers are extensively used in data centers and automotive industries due to increasing demands for high power density and efficiency. Within the discourse concerning the reduction of losses at the secondary side, the significance of shortening the current loop and minimizing parasitic inductance among output capacitors has been subject to in-depth exploration. Building upon these foundations, this paper introduces a more precise terminal model, offering a deeper analysis of the conditions for capacitors ringing oscillation, while emphasizing the neglected importance of symmetry in the design process. Modeling results indicate that optimizing terminal resistances with consideration for both symmetry and the reduction of parasitic inductance results in a substantial reduction. In this study, the optimized terminal resistance can be lowered to a remarkable 34% of the original design, significantly enhancing the overall efficiency of the converter. 

Symmetrical Termination Structure for Matrix Transformer in High Power Density Applications

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GaN-based Interleaved CRM Totem-pole PFC Rectifier with Variable-step Adaptive ZVS Control

1.5kW LLC Resonant Converter with improved interleaved winding structure and core structure

S-shaped coil, Four Column Design Based On Interleaved Parallel PFC Uncoupled Inductor

Symmetrical Termination Structure for Matrix Transformer in High Power Density Applications