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A two-phase buck–boost converter utilizing dual interleaving is presented in this article. The dual interleaving consists of an interphase transformer (IPT) that doubles the ripple frequency together with two conventional buck–boost switching arms, mitigating the inductor ripple current and aiding to increase the power density of the converter. A description of the design and selection of the power devices is presented for a 32-kW, 75-kHz dual interleaved SiC prototype with an IPT, such that a power density of 7.4 kW/kg is achieved. The operation of the circuit is verified experimentally using a prototype with 315–385 V supply range and 350-V output voltage, achieving 97.1% peak efficiency at 32 kW. The experiments reveal that the interleaved coupled currents are equalized without an active balancer. [ABSTRACT FROM AUTHOR]

A split-core technique is proposed to mitigate the gap losses in high-frequency nanocrystalline cores, which enables significant size reductions in thermally limited designs. Finite element analysis is used to examine the gap loss dependence on core width D revealing a nonlinear relationship of the form loss ∝ $D^{\alpha }$. α is approximately constant for frequencies of 10–200 kHz over the range of core widths typically used in power electronics, but α increases with gap length. Splitting the core into a number of subcores can therefore provide significant reductions in gap loss, especially with larger gap lengths. The results from a 300-A (peak), 200-A (continuous) inductor show that with three subcores and a gap length of 4 mm, the gap losses are reduced by 50%, and the hot-spot temperature is reduced by 24.5 °C. Using the technique it is estimated that the original inductor weight could be reduced by 40% with four split cores, making a significant impact on converter power density. [ABSTRACT FROM AUTHOR]

Finite element analysis is used to examine the gap losses that occur in finely laminated nanocrystalline inductor cores under high-frequency operation. The losses are seen to be concentrated in the region of the air gap and the dependence of the losses on key design parameters and operating conditions is explored. The results show that gap losses can be significant in this type of core, creating hot spots around the gap, and the losses are not accurately predicted by established design equations for low-frequency laminated cores. A modified loss equation is proposed. Validation is provided by measurements on a 300-A, 60 kHz inductor. [ABSTRACT FROM AUTHOR]

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]