This dissertation focuses on the development of low-temperature co-fired ceramics (LTCC) technology for power converter magnetics integration. Because magnetic samples must be fabricated with thick conductors for power applications, the conventional LTCC process is modified by cutting trenches in the LTCC tapes where conductive paste is filled to produce thick conductors to adapt to this requirement. Characterization of the ceramic magnetic material is performed, and an empirical model based on the Steinmetz equation is developed to help in the estimation of losses at frequencies between 1 MHz to 4 MHz, operating temperature between 25 °C and 70 °C, DC pre-magnetization from 0 A/m to 1780 A/m, and AC magnetic flux densities between 5 mT to 50 mT. Temperature and DC pre-magnetization dependence on Steinmetz exponents are included in the model to describe the loss behavior. In the development of the LTCC chip inductor, various geometries are evaluated. Rectangular-shaped conductor geometry is selected due to its potential to obtain a much smaller footprint, as well as the likelihood of having lower losses than almond-shaped conductors with the same cross-sectional area, which are typically a result of screen printing. The selected geometry has varying inductance with varying current, which helps improve converter efficiency at light load. The efficiency at a light-load current of 0.5 A can be improved by 30 %. Parametric variation of inductor geometry is performed to observe its effect on inductance with DC current as well as on converter efficiency. An empirical model is developed to describe the change in inductance with DC current from 0 A to 16 A for LTCC planar inductors fabricated using low-permeability tape with conductor widths between 1 mm to 4 mm, conductor thickness 180 μm to 550 μm, and core thickness 170 μm to 520 μm. An inductor design flow diagram is formulated to help in the design of these inductors. Configuring the inductor as the substrate carrying the semiconductor and the other electronic components is a next step to freeing the surface area of the bulky component and improving the power density. A conductive shield is introduced between the circuitry and the magnetic substrate to avoid adversely affecting circuit operation by having a magnetic substrate in close proximity to the circuitry. The shield helps reduce parasitic inductances when placed in close proximity to the circuitry. A shield thickness in the range of 50 μm to 100 μm is found to be a good compromise between power loss and parasitic inductance reduction. The shield is effective when its conductivity is above 10⁷ S/m. When a shield is introduced between the inductor substrate and the circuitry, the sample exhibits a lower voltage overshoot (47 % lower) and an overall higher efficiency (7 % higher at 16 A), than an inductor without a shield. A shielded active circuitry placed on top of an inductive substrate performs similarly to a shielded active circuitry placed side-by-side with the inductor. Using a floating shield for the active circuitry yields a slightly better performance than using a grounded shield. / Ph. D.

The trend in isolated DC/DC bus converters is to increase the output power in the same brick form factors that have been used in the past. Traditional intermediate bus converters (IBCs) use silicon power metal oxide semiconductor field effect transistors (MOSFETs), which recently have reached the limit in terms of turn on resistance (RDSON) and switching frequency. In order to make the IBCs smaller, the switching frequency needs to be pushed higher, which will in turn shrink the magnetics, lowering the converter size, but increase the switching related losses, lowering the overall efficiency of the converter. Wide-bandgap semiconductor devices are becoming more popular in commercial products and gallium nitride (GaN) devices are able to push the switching frequency higher without sacrificing efficiency. GaN devices can shrink the size of the converter and provide better efficiency than its silicon counterpart provides. A survey of current IBCs was conducted in order to find a design point for efficiency and power density. A two-stage converter topology was explored, with a multiphase buck converter as the front end, followed by an LLC resonant converter. The multiphase buck converter provides regulation, while the LLC provides isolation. With the buck converter providing regulation, the switching frequency of the entire converter will be constant. A constant switching frequency allows for better electromagnetic interference (EMI) mitigation. This work includes the details to design and implement a hard-switched multiphase buck converter with planar magnetics using GaN devices. The efficiency includes both the buck efficiency and the overall efficiency of the two-stage converter including the LLC. The buck converter operates with 40V - 60V input, nominally 48V, and outputs 36V at 1 kW, which is the input to the LLC regulating 36V – 12V. Both open and closed loop was measured for the buck and the full converter. EMI performance was not measured or addressed in this work. / Master of Science / Traditional silicon devices are widely used in all power electronics applications today, however they have reached their limit in terms of size and performance. With the introduction of gallium nitride (GaN) field effect transistors (FETs), the limits of silicon can now be passed with GaN providing better performance. GaN devices can be switched at higher switching frequencies than silicon, which allows for the magnetics of power converters to be smaller. GaN devices can also achieve higher efficiency than silicon, so increasing the switching frequency will not hurt the overall efficiency of the power converter. GaN devices can handle higher switching frequencies and larger currents while maintaining the same or better efficiencies over their silicon counterparts. This work illustrates the design and implementation of GaN devices into a multiphase buck converter. This converter is the front end of a two-stage converter, where the buck will provide regulation and the second stage will provide isolation. With the use of higher switching frequencies, the magnetics can be decreased in size, meaning planar magnetics can be used in the power converter. Planar magnetics can be placed directly inside of the printing circuit board (PCB), which allows for higher power densities and easy manufacturing of the magnetics and overall converter. Finally, the open and closed loop were verified and compared to the current converters that are on the market in the 48V – 12V area of intermediate bus converters (IBCs).

Thesis (MBA)--Stellenbosch University, 2001. / ENGLISH ABSTRACT: Eriez Magnetics, a manufacturer of specialized magnetic and associated equipment, is well positioned in terms of image and reputation. However, a growing number of low cost competitors are continuously eroding its Market share. The objective of the study was to perform a comprehensive situational analysis, and identify key issues that are necessary for Eriez to improve its competitive position. Various analytic tools and filters were used to analyse the company information, which was predominantly obtained form structured interviews. The key issues identified were: a. No clear and visible vision, mission and objectives agreed and understood by all in organisation. b. No common value system threading through organisation. c. Lack oftrust between workers and management. d. No integrated information system to enable sharing of information. e. Lack of formal and visible performance. f. No formal quality plan in workshop that is adhered to for every job. g. Lack of concerted customer focus due to understaffed sales and marketing team. h. Potential for the diverse product range to be streamlined. i. Lack of Staff and Agent Training. j. Lack of Employee encouragement to submit ideas to enhance performance. In order to regain its position as the market leader, it needs to focus strongly on its people management, internal processes, customer service and core products, as detailed in this report. The Balance Scorecard is a tool that Eriez SA must consider using to actively monitor key variables identified that will enhance the company's competitive position. The next phase of the project is syndicating these findings and recommendations with Eriez SA top management with a view of setting up an implementation plan. / AFRIKAANSE OPSOMMING: Eriez Magnetics, a maatskappy wat gespesialiseerde magnetiese en assosieerde toerusting vevaardig het 'n goeie reputasie en beeld wereld wyd. Hulle mark word huidiglik bedreig in Suid Afrika deur 'n groeiende aanslag van lae koste vevaardigers. Die uiteensetting van die skrif is gegrond op 'n analiese van Eriez se huidige situasie, om sleutel items te identifiseer wat hulle in staat sal stel om hulle mark posisie te verbeter. Informasie vanuit die maatskappy was grooteliks bekom deur gestruktureerde onderhoude met sleutel staf. Verskillende analietese applikasie toerusting was gebruik om die maatskappy se informasie te evalueer. Sleutel punte was as volg:: a. Daar is geen duidelike, sigbare visie of rigting wat almal in die organisasie kan verstaan en identifiseer mee nie. b. Geen waarde sisteem was opsigtilik in die organisasie. c. Daar bestaan 'n duidelike wantroue tussen werkgewer en werknemer. d. Daar is geen sentrale informasie stelsel wat werknemers toegang tot het nie. e. Geen formele werk verrigtings stelsel. f. Geen formele kwaliteits standaarde wat toegepas word nie. g. Bemarking en verkope span is erg beperk in terme van staf, dit impak op kliente fokus. h. Hulle diverse produk reeks behoort krities ondersoek te word. i. Minimale staf en agente opleidings programme in plek. j. Werknemers word nie aangepor om konstruktiewe idees voor te lê nie. Indien Eriez sy posisie as mark leier wil herwin, sal hy streng fokus op sy bestuur, interne prosesse, kliente diens en kern produkte moet plaas, soos beskryf in die verslag. Eriez SA word ook aangeraai om die gebalanseerde telkaart metode toe te pas, wat fokus sal plaas op koste besparing en ook sy kompeterende posisie verhoog. Die volgende fase is om die bevindinge, soos saamgevat in die verslag, voor te lê aan Eriez SA hoofbestuur en om 'n implementeerings program daar te stel.

Present models of Holocene estuary evolution are driven largely by changes in relative sea-level (RSL) with little reference to long-term changes in fluvial regime and regional climate. Recent US studies of estuarine sequences have shown that decadal-centennial scale fluctuations in river discharge and freshwater inflow can be inferred by changes in estuarine palaeosalinity and that the timing of these events reflect changes in regional precipitation. It is therefore becoming apparent that estuarine sequences may hold an archive of mid-late Holocene climate change information, as well as being recorders of RSL change. The principal aim of this study is to produce a palaeosalinity-based climate record for southern England during the late Holocene, based on changes in climate-driven freshwater influx into the estuarine environment. The late Holocene palaeosalinity record of the inner Taw Estuary will be reconstructed using diatom salinity index as a proxy for salinity. Nine periods of below-average or above-average palaeosalinity have been recognised in the Taw Estuary since 300 cal.yr.BC. Four intervals of high river discharge are identified at 520-780, 850-1030, 1215-1315, and 1420-1900 cal.yr.AD. Five intervals of low river discharge are identified at 300-520, 780-850, 1030-1215, 1315-1420, and 1900-2000 cal.yr.AD. This shows that there has been significant climatic variation in southern Britain since c.300 cal.yr.AD, with climatic shifts evident in the estuarine record. In order to validate this record, the fluvial geomorphic history of the lower Taw valley was also investigated. There is a strong correspondence between the dry and wet climatic periods identified in the estuary and the geomorphic fluvial history and flood record of the lower Taw valley. Comparisons with other proxy climate records in the UK and Europe show a high degree of correspondence with the Taw Estuary palaeosalinity-based climate record. As the inner estuary environment will also be influenced by RSL change during the late Holocene, RSL change since c.6600 cal.yr.BP was successfully reconstructed in the Taw Estuary, with eleven new validated SLIPs providing evidence of former MSL. The magnitude and rates of RSL rise in north Devon are compared with other RSL records in southern Britain, suggesting that the isostatic history is similar to other areas bordering the Bristol Channel and with the central south coast of England. Fluctuations in palaeosalinity in the late Holocene are seen to be mainly controlled by centennial-scale changes in climate-driven river discharge, rather than RSL change.

This dissertation investigates a new design for a magnetostrictive actuator that employs individually controlled coils distributed axially along the magnetostrictive rod. As a quantitative goal, the objective is to show that the multi-coil actuator can operate effectively at frequencies as high as 10,000 Hz with 900 N force and 50 microns of displacement. Conventional, single coil actuators with the same parameters for force and displacement develop significant attenuation in their response at frequencies above the first longitudinal vibration resonance at about 2750 Hz. The goal of the research is to investigate whether multiple coils can effectively increase the frequency range a least four times the range of conventional magnetostrictive actuators. This document derives a new mathematical model of the actuator that represents the spatial distributions of magnetic field and vibration, devises a control design that takes advantage of the multiple inputs to control the displacement of the actuator while consuming minimum electrical power, and describes a prototype multi-coil actuator and experimental system developed to test the idea. The simulations of the multi-coil actuator and control design demonstrate successful transient operation of the actuator over the targeted frequency range with feasible levels of input power and current. Experimental tests of the design, although limited by a computer sampling rate less than 10,000 Hz, are able to validate the predictions of the developed model of the actuator and reproduce the simulated control performance within the constraints of the experimental system.

As part of the natural evolution and continued optimisation of their designs, current and future magnetic recording heads, used and proposed in technologies such as perpendicular recording, shingled magnetic recording and two-dimensional magnetic recording, often exhibit asymmetry in their structure. They consist of two semi-infinite poles separated by a gap (where the recording field is produced), with an inner gap faces inclined at an angle. Modelling of the fields from asymmetrical structures is complex, and no explicit solutions are currently available (only implicit conformal mapping solutions are available for rational inclination angles). Moreover, there is limited understanding on the correlation between the gap corner angle and the magnitude, distribution and wavelength response of these head structures. This research was therefore set out to investigate approximate analytical and semi-analytical methods for modelling the magnetic potentials and fields of two-dimensional symmetrical and asymmetrical magnetic recording heads, and deliver a quantitative understanding of the behaviour of the potentials and fields as functions of gap corner angles. The accuracy of the derived expressions (written in terms of the normalised root-mean-square deviation) was assessed by comparison to exact available solutions for limited cases, and to finite-element calculations on Comsol Multiphysics. Two analytical methods were derived to approximately model the fields from two-dimensional heads with tilted gap corners in the presence and absence of a soft magnetic underlayer (SUL): in the first method, the potential near a single, two-dimensional corner held at a constant potential is derived exactly through solution of Laplace's equation for the scalar potential in polar coordinates. Then through appropriate choice of enclosing boundary conditions, the potentials and fields of two corners at equal and opposite potentials and displaced from each other by a distance equal to the gap length were superposed to map the potential and field for asymmetrical and symmetrical heads. For asymmetrical heads, the superposition approximation provided good agreement to finite-element calculations for the limited range of exterior corner angles 0 from 0 (right-angled corner) to 45, due to the mismatch of surface charge densities on both poles for this geometry. For symmetrical head structures, the superposition approximation was found to yield remarkable agreement to exact solutions for all gap corner orientations from 0 (right-angled head) to 90 ("thin" gap head). In the second method derived in this research for modelling asymmetrical heads involved using a rational function approximation with free parameters to model the surface potential of asymmetrical heads. The free parameters and their functional dependence on corner angle were determined through fitting to finite-element calculations, enabling the derivation of analytical expressions for the magnetic fields that are in good agreement with exact solutions for all corner angels (0 to 90). To complement the two approximate methods for modelling the fields from asymmetrical and symmetrical heads, a new general approach based on the sine integral transform was derived to model the reaction of soft underlayers on the surface potential or field of any two-dimensional head structure, for sufficiently close head-to-underlayer separations. This method produces an infinite series of correction terms whose coefficients are functions of the head-to-underlayer separation and gap corner angle, that are added to the surface potential or field in the absence of an underlayer. This new approach demonstrated good agreement with finite-element calculations for sufficiently close head-to-underlayer separations, and with the classical Green's functions solutions for increasing separations. Using the derived analytical method and explicit expressions in this work, an understanding of the nature of the magnetic fields and their spectra as functions of the gap corner angles is gained. This understanding and analytical theory will benefit the modelling, design and optimisation of high performance magnetic recording heads.

Contactless Electric Vehicle (EV) charging based on magnetic resonant induction is an emerging technology that can revolutionize the future of the EV industry and transportation systems by enabling an automated and convenient charging process. However, in order to make this technology an acceptable alternative for conventional plug-in charging systems it needs to be optimized for different design measures. Specifically, the efficiency of an inductive EV charging system is of a great importance and should be comparable to the efficiency of conventional plug-in EV chargers. The aim of this study is to develop solutions that contribute to the design enhancement of inductive EV charging systems. Specifically, generalized physics-based design optimization methods that address the trade-off problem between several key objectives including efficiency, power density, misalignment tolerance, and cost efficiency considering critical constraints are developed. Using the developed design methodology, a 3.7kW inductive charging system with square magnetic structures is investigated as a case study and a prototype is built to validate the optimization results. The developed prototype achieves 93.65% efficiency (DC-to-DC) and a power density of 1.65kW/dm3. Also, self-tuning power transfer control methods with resonance frequency tracking capability and bidirectional power transfer control are presented. The proposed control methods enhance the efficiency of power converters and reduce the Electromagnetic Interference (EMI) by enabling soft-switching operations. Several simplified digital controllers are developed and experimentally implemented. The controllers are implemented without the use of DSP/FPGA solutions. Experimental tests show that of the developed simplified controllers can effectively regulate the power transfer around the desired value. Moreover, the experiments show that compared to conventional converters, the developed converters can achieve 4% higher efficiency at low power levels. Moreover, enhanced matrix converter topologies that can achieve bidirectional power transfer and high efficiency with a reduced number of switching elements are introduced. The self-tuning controllers are utilized to design and develop control schemes for bidirectional power transfer regulation. The simulation analyses and experimental results show that the developed matrix converters can effectively establish bidirectional power transfer at the desired power levels with soft-switching operations and resonance frequency tracking capability. Specifically, a direct three-phase AC-AC matrix converter with a reduced number of switches (only seven) is developed and built. It is shown that the developed converters can achieve efficiencies as high as 98.54% at high power levels and outperform conventional two-stage converters.

This dissertation demonstrates the first of its kind distributed magnetic field sensor based on a fiber optic distributed acoustic sensing (DAS) scheme. Ferromagnetic nickel and Metglas® were dispersed internally within a fiber optic preform and then drawn on an in-house fiber optic draw tower to lengths in the kilometers. Due to the close proximity of the ferromagnetic metals and fiber optic core, the magnetostrictive strain response of the ferromagnetic materials when exposed to a magnetic field would perturbate within the fiber cladding and transfer that strain, internally, to the fiber optic core. Strain resulting from the magnetostrictive effect allows the DAS based sensor to accurately translate strain into readable magnetic field data. Due to the high sensitivity seen in this sensor design, multiparameter sources, acoustic and magnetic fields, were tested and validated and a three dimensional magnetic-field vector sensor was proposed. Numerical analysis of the novel sensor design was first implemented using COMSOL Multiphysics, where inputs such as magnetostrictive element shape, size, distance, and number were first investigated. Upon optimizing system constraints, the sensor design was further modified such that single mode operation was consistent across multiple fiber draws while retaining high strain transfer from the ferromagnetic elements to the fiber optic core. Ferromagnetic material selection was evaluated as a function of the saturation magnetostriction constants and a total of 4 modules were used to fully characterize the complex physics involved in this sensor design. All fabrication and testing were performed in-house using a full scale 3-story fiber draw tower and custom environmental testing stations to imitate naturally occurring events such as magnetic or acoustic point sources. A unique stacking method was used to embed ferromagnetic nickel and Metglas® into a fiber optic preform which when combined with a custom fiber draw process resulted in consistent multi-material fibers drawn to lengths of 1-km. In-house testing facilities included different types of electromagnetic generators, in addition to a soil test bed, and an outdoor test bed which allowed 100 meters of fiber to be tested simultaneously. All tested sensors demonstrated high strain transfer capabilities on the order of 0.01-10 μϵ depending on the materials used, ferromagnetic rod number, and core to metal spacing. Due to the sensitivity of the system the difference between AC and DC was distinct, and directional magnetostriction was studied. Transverse and longitudinal magnetic wave propagation was controlled through a solenoid and rectangular Helmholtz coil, both built in-house. A three-dimensional magnetic field vector sensor was proposed due to the success of the magnetic field sensor, and a design was proposed and initially tested to validate direction as a function of field strength and distance. To summarize, this dissertation explores the first fully distributed magnetic field sensor using DAS based techniques and one of the first multi-material fiber draw processes which can produce consistent single mode fiber up to 1-km. Due to extensive FEA modeling, multiple iterations of the magnetic sensor were fully characterized and an equation describing the relationship between sensor design and strain transfer has been created and validated experimentally. Multi-parameter tests including acoustic and magnetic fields were implemented and an algorithm was developed to separate the mixed signals. Finally, a test was performed to demonstrate the feasibility of sensing magnetic fields directionally. Cumulative results demonstrate a high-quality sensor alternative to current designs which may surpass other magnetic sensors due to innate multi-parameter capabilities, in addition to the inexpensive production cost and extremely long operating lengths. / Doctor of Philosophy / This dissertation demonstrates the first of its kind distributed magnetic field sensor based on a fiber optic distributed acoustic sensing (DAS) scheme. Ferromagnetic nickel and Metglas® were dispersed internally within a fiber optic preform and then drawn on an in-house fiber optic draw tower to lengths in the kilometers. Due to the close proximity of the ferromagnetic metals and fiber optic core, the magnetostrictive strain response of the ferromagnetic materials when exposed to a magnetic field would perturbate within the fiber cladding and transfer that strain, internally, to the fiber optic core. Strain resulting from the magnetostrictive effect allows the DAS based sensor to accurately translate strain into readable magnetic field data. Due to the high sensitivity seen in this sensor design, multiparameter sources, acoustic and magnetic fields, were tested and validated and a three dimensional magnetic-field vector sensor was proposed. Numerical evaluation of the sensing structure was perused before experimental testing using COMSOL Multiphysics. Experimental and numerical evaluations were compared and showed a high degree of certainty which allowed expedited design modifications. Sensor characterization included scanning electron microscopy, and electron diffraction spectroscopy, which provided insight into material composition and fiber polishing quality. Due to the high-quality results attained in the combined acoustic and magnetic field tests, a final design was proposed to gather magnetic field data as a vector, showing both magnitude and direction. The 3D magnetic field vector sensor was partially validated based on a test which compared intensity with distance and a design and methodology was proposed to fully test and characterize this design. To summarize, a novel magnetic field sensor, capable of multi-parameter sensing, was proposed and tested experimentally and numerically resulting in a robust and highly sensitive design. The work presented here provides some of the first insights into multi-material fiber fabrication, an equation which provides an estimated relationship between magnetostrictive strain transfer onto a fiber optic core and the perceived DAS based sensor results, as well as a first of its kind multi-parameter distributed acoustic and magnetic field sensor.

Rising fuel costs and concerns about air pollution have significantly increased interest in electric vehicles (EVs). EVs are equipped with rechargeable batteries that can be fully recharged by connecting to an external electrical source. However, the wider adoption of EVs is hindered by the need for an on-board charger system that is both lightweight and efficient. EVs utilize two main charging methods: on-board chargers (OBC) for regular charging and off-board (fast) chargers for quick refills of battery pack. Most EVs currently use 400V battery packs paired with 6.6kW or 11kW OBCs, while larger vehicles with over 100 kWh battery packs employ 16.5kW or 19.2kW OBCs, constrained by household voltage and current limits. Some manufacturers are transitioning to 800V battery packs to lower costs and enhance fast charging capabilities, necessitating the development of 800V OBCs with high efficiency and power density. For household use, EVs can charge via OBC in a grid-to-vehicle transfer and can supply energy back to the home or grid (vehicle-to-grid) for emergency use or to support smart grid functionalities, requiring bidirectional OBCs. Advanced power semiconductor devices have been instrumental in advancing power conversion technology. The introduction of power semiconductor devices based on wide bandgap (WBG) materials marks a revolutionary shift, offering potential improvements over silicon-based devices. These WBG devices are capable of achieving higher efficiency, and higher power density in power conversion at higher operation frequency. Elevating the switching frequency diminishes the voltage-second across the transformer, facilitating the utilization of printed-circuit-board (PCB) technology for the windings as opposed to Litz wire implementations. Compared to traditional Litz wire-based transformers, the manufacturing process is significantly streamlined, and the management of parasitic is considerably more straightforward. Furthermore, the integration of resonant inductors with PCB-based transformer results in a reduction in the overall number of magnetic components and improved power density. This dissertation focuses on the DC/DC conversion stage of a bi-directional battery charger. It aims to achieve high power density and high efficiency using a PCB-based integrated transformer, enhancing manufacturing processes. The dissertation details the specific accomplishments in this area: Firstly, a two-stage on-board charger structure for 800 V battery EVs is proposed. The first stage is a four-phase bridgeless totem pole AC/DC converter working at critical conduction mode (CRM) so that soft switching can be achieved for all the fast switches. The second stage is single phase CLLC (1PCLLC) converter which is attractive due to its less component counts of devices and driver circuits. A novel matrix integrated transformer with controllable built-in leakage inductance for bi-directional 1PCLLC converter was proposed. Integrating three UI-core-based (1UI-based) elemental transformers with non-perfectly interleaved winding structures into one 3UI-based integrated transformer can reduce the core loss significantly with a smaller footprint compared with three EI-core-based integrated transformers. The proposed integrated magnetics can be scalable for higher voltage and higher power converters by assembling more 1UI-based elemental transformers. A SiC-based 1PCLLC converter prototype operating at 250-kHz switching frequency for 11-kW OBC applications was built with the proposed integrated transformer, and it can achieve a power density of 250 W/in3 with maximum efficiency of 98.4%. Secondly, the challenge of increased common mode (CM) noise after adopting PCB-based windings in the design was discussed. The inter-winding capacitors between the primary and secondary windings act as a conduction path for high dv/dt CM noise, which can lead to electromagnetic interference (EMI) issues. To address this, a winding cancellation method for an integrated matrix transformer in a 1PCLLC converter was proposed and validated. This approach was tested in an 11-kW 1PCLLC converter. The EMI measurement results align with the analysis, confirming the effectiveness of the proposed method, which achieved a reduction in CM noise by 17dB. Furthermore, the 1PCLLC converter, incorporating the proposed planar matrix integrated transformer and winding cancellation technique, attained a power density of 420 W/in³ and a peak efficiency of 98.5%. Thirdly, to enhance efficiency further, the 1PCLLC converter is substituted with the proposed three-phase CLLC (3PCLLC) resonant converter equipped with three-phase rectifiers. The 3PCLLC converter becomes more promising for high power applications as its lower RMS current stress and automatic current sharing capabilities. It can achieve soft switching under all conditions. In addition, due to the symmetrical resonant tank, it is more suitable for bi-directional operation. Variable DC-link voltage is adopted so that the DC/DC stage can always work at its optimized point, providing best efficiency for the entire battery voltage. An improved core structure for the three-phase integrated transformer was proposed to reduce the core loss and simplify the magnetic components by integrating three primary resonant inductors, three secondary resonant inductors and three transformers into one magnetic component. A systematic method of converter design which includes the design of integrated transformer, converter loss optimization was adopted to design an 11kW 3PCLLC resonant converter. A SiC-based 3PCLLC converter prototype operating at 250-kHz switching frequency for 11-kW OBC applications was built with the proposed integrated transformer, and it can achieve a power density of 330 W/in3 with peak efficiency of 98.7%. Fourthly, the power level of OBC continues to increase to make up the large capacitance battery pack inside the EVs to relief the concern of mileage range. To address this challenge of higher power, a scalable matrix integrated transformer for multi-phase CLLC converter was proposed. A universal method of integrating magnetizing inductance with built-in leakage inductance based on multiple perfectly coupled transformers (PCTs). The integration of built-in leakage inductance can be achieved by connecting several PCTs using a standardized core type for cost considerations or can be further integrated into a customized core with interleaved magnetomotive force polarities across transformer legs to achieve better flux distribution and smaller core loss. The proposed concept can be applied to single-input single-output, and multiple-inputs multiple-outputs integrated transformer applications. A 3x3 PCTs-based integrated transformer built with PCB windings was designed for a 3PCLLC resonant converter, which integrates three primary resonant inductors, three secondary resonant inductors, and three transformers into one magnetic core to simplify the complexity of the converter. The effectiveness of the proposed concept was demonstrated through a high-efficiency, high-power density 3PCLLC DC/DC converter for an 800V 16.5kW OBC. The designed converter can achieve a power density of 500 W/in3 and a peak efficiency of 98.8%. / Doctor of Philosophy / Rising fuel costs and concerns about air pollution have significantly increased interest in electric vehicles (EVs). EVs are equipped with rechargeable batteries that can be fully recharged by connecting to an external electrical source. However, the wider adoption of EVs is hindered by the need for an on-board charger system that is both lightweight and efficient. The dissertation presents advances in OBC technology to address these challenges, focusing on the development of efficient, high-power density OBCs suitable for various EV applications. EVs utilize two main charging methods: on-board chargers (OBC) for regular charging and off-board (fast) chargers for quick refills of battery pack. Most EVs currently use 400V battery packs paired with 6.6kW or 11kW OBCs, while larger vehicles with over 100 kWh battery packs employ 16.5kW or 19.2kW OBCs, constrained by household voltage and current limits. Some manufacturers are transitioning to 800V battery packs to lower costs and enhance fast charging capabilities, necessitating the development of 800V OBCs with high efficiency and power density. For household use, EVs can charge via OBC in a grid-to-vehicle transfer and can supply energy back to the home or grid (vehicle-to-grid) for emergency use or to support smart grid functionalities, requiring bidirectional OBCs. Advanced power semiconductor devices have been instrumental in advancing power conversion technology. The introduction of power semiconductor devices based on wide bandgap (WBG) materials marks a revolutionary shift, offering potential improvements over silicon-based devices. These WBG devices are capable of achieving higher efficiency, and higher power density in power conversion at higher operation frequency. Elevating the switching frequency diminishes the voltage-second across the transformer, facilitating the utilization of printed circuit board (PCB) technology for the windings as opposed to Litz wire implementations. Compared to traditional Litz wire-based transformers, the manufacturing process is significantly streamlined, and the management of parasitic is considerably more straightforward. Furthermore, the integration of resonant inductors with PCB-based transformer results in a reduction in the overall number of magnetic components and improved power density. Addressing cost concerns, a novel, cost-effective single-phase converter design was proposed, achieving high efficiency with integrated magnetics. Additionally, the research tackled the challenge of electromagnetic interference (EMI) through a winding cancellation technique, significantly reducing common-mode noise and further improving the converter's performance. The research introduces an improved core structure for a three-phase integrated transformer, significantly reducing core loss and simplifying the design by combining multiple components into a single unit. This approach facilitated the creation of a high-efficiency, SiC-based converter prototype, demonstrating remarkable power density and peak efficiency compared with state-of-the-art solutions. To accommodate the increasing power requirements of OBCs, a scalable, matrix integrated transformer design was developed for multi-phase converters, optimizing cost and performance. This design simplifies the converter architecture, enhancing efficiency and power density, and is adaptable to both single and multiple output applications. These advancements offer promising solutions to the challenges hindering the wider adoption of EVs. The dissertation underscores the potential of advanced power conversion technologies, including the application of WBG devices, integrated magnetics to streamline converter design and enhance both the efficiency and power density of battery chargers.

Current source is used in auxiliary power supplies, battery chargers, and LED drivers. The battery chargers are required to provide constant current within a wide output voltage range, similar to LED drivers. The load-independent (LI) Class-E inverter is a promising topology for such applications since it can realize zero-voltage switching (ZVS) within a wide load range. Class-E current source can be achieved by converting constant voltage (CV) Class-E inverter to current source with a trans-susceptance network or using parallel resonant topology. The design and analysis of LI Class-E inverters usually assume a high-Q resonant load tank so that the load current/voltage is sinusoidal. While this is the case in RF applications, it's not required in DC-DC power conversion. Besides, high-Q design leads to high inductance and increased voltage/current stress on the resonant components, increasing converter volume, loss, and cost. This work aims to provide a design guideline for the CC Class-E inverter when significant harmonics are present by reflecting the trade-off between load range and voltage stress, with the help of a modified frequency domain analysis method to eliminate the iteration existing in the time domain analysis. Output current variation and voltage stress can be automatically quantified when circuit parameters vary. Generalized load range contours are obtained to guide the circuit design. With the help of the analysis, a 10-W dual-output Class-E gate power supply is designed with optimized magnetics and reduced isolation capacitance. Compared with CC Class-E based on trans-susceptance network, the parallel resonant CC Class-E inverter has smaller part counts due to its low-order resonant network. However, the current topology suffers from limited maximum output power. In this work, a coupled-inductor based parallel resonant CC Class-E inverter is proposed with more than 2 times maximum power without increasing part counts. / Doctor of Philosophy / Current source is used in auxiliary power supplies, battery chargers, and LED drivers. The battery chargers are required to provide constant current within a wide output voltage range, similar to LED drivers. The load-independent (LI) Class-E inverter is a promising topology for such applications since it can realize zero-voltage switching (ZVS) within a wide load range. This work aims to provide a new design guideline for the CC Class-E inverter when significant harmonics are present by reflecting the trade-off between load range and voltage stress, with the help of a modified frequency domain analysis method to eliminate the iteration existing in the time domain analysis. Output current variation and voltage stress can be automatically quantified when circuit parameters vary. Generalized load range contours are obtained to guide the circuit design. With the help of the analysis, a 10-W dual-output Class-E gate power supply is designed with optimized magnetics and reduced isolation capacitance. Compared with CC Class-E based on trans-susceptance network, the parallel resonant CC Class-E inverter has smaller part counts due to its low-order resonant network. However, the current topology suffers from limited maximum output power. In this work, a coupled-inductor based parallel resonant CC Class-E inverter is proposed with more than 2 times maximum power without increasing part counts.