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An investigation is described into the optimization of multi-phase, high power, bi-directional DC-DC interleaved converters suitable for Electric Vehicle (EV) applications. Two dual-interleaved topologies were considered initially for the optimization, the main difference being the magnetic devices: either discrete inductors (DI) or an Interphase Transformer (IPT). The comparison used a comprehensive multi-objective design optimization procedure for an 80 kW case study. High performance inductors comprising a split-core structure and dual-foil windings to reduce losses, and a 180 °C core, enabled the DI to be competitive with IPT in terms of power density and efficiency. The optimized designs are validated experimentally with an 80 kW bi-directional SiC DC-DC converter, achieving a power density of 31.4 kW/L and specific power of 15.7 kW/kg. The study is then extended to 100-kW three and four-phase interleaved topologies. [ABSTRACT FROM AUTHOR]

The design of a 200-A, all-SiC power-module-based on bipolar junction transistor devices is described, and the impact of the module is assessed on the performance of a 50-kW dc-dc converter for electric vehicle applications, particularly the overall weight and efficiency. Using a hard-switching dual-interleaved topology, which has proven high efficiency and high-power density capability, the operation of a 50-kW, 75-kHz all-SiC converter is compared with that of an insulated-gate bipolar transistor-based silicon converter, switching at 25 kHz, each providing 600-V output. The results show that the total losses are reduced by almost 40%, whilst the overall weight is reduced by 27%, achieving a power density of 10.5 kW/kg. Experimental results of the SiC converter operating at 220-600 V, 52.8 kW are provided, showing an efficiency of 97%. [ABSTRACT FROM AUTHOR]