A dc-dc converter with integrated Magnetics and sensor and ZVS, ZCS circuit topology in one package to reduce the interconnects and the losses is proposed. The custom made three dimensional magnetic design will allow us to increase the switching frequency to >500kHz, while maintaining >92% efficiency at 12V output. The power devices and magnetic will be utilizing the high temperature common package with Direct Bond Copper, substrate for better heat transfer. The power converter will have integrated diagnostics and operation status reporting. The base plate will be integrated with the cooling fins to optimize the heat rejection. The proposed design is cost effective for low volume production and it is designed for dual use of DOD and heavy duty hybrid commercial vehicles and telecom. US Hybrid similar design dc-dc converts has passed the NEBS, telecommunications qualification, which includes the EMI/EMC, shock, vibration and drop test as well as thermal cycling. A high bandwidth control loop to provide fast transient with ramp compensated current regulated, phase shift ZVS converter with current doubler output inductors to minimize the stored energy on the unit input and out to enhance the transient response is considered.
Keywords: Can, Can, High Power Density, Zcs, Zvs, Dc-Dc, Integrated Cooling
