Design and integration of inductive components for a high-frequency 11 kW / 800 V off-board charger for electric vehicles

In this paper an air-cooled 11 kW / 800 V off-board charger with a target power density of 2.2 kW / liter (36 W/in3) is presented. A soft-switched silicon-carbide (SiC)-based power electronic is utilized operating at a high switching frequency of 1 MHz. Thus, the volume of the required transformer for galvanic isolation is considerably reduced. For inductive component design novel low-loss power ferrite materials are applied which are optimized to operate at high frequencies. For electromagnetic compatibility (EMC) an active filter stage is developed and integrated in the total volume of 5 liter.