Unique AC-link Power Converter Design with a Small, Lightweight, High-Frequency Internal Transformer

In Phase I, we propose to design a 300kW DC-DC converter for hybrid vehicles that operates at 92% efficiency, with 100°C coolant inlet temperature, and fits within 50L (6kW/L). Transitioning to the use of Silicon Carbide switching technology when it becomes available should allow increases in power density to 8kW/L. Our unique innovation is using the AC-link power conversion technology, which provides extremely low switching losses and minimal component count. AC-link is a softswitching technology, which minimizes switching losses resulting in reduced active switch and thermal management requirements. AC-link is currently being used in a similar project to build a 250kW power-dense DC-DC converter for the Air Force's Active Denial Technology; these efforts will be leveraged for this project. We will also construct a 10kW bench-scale unit in Phase I to prove the feasibility of the system. In Phase II, we will develop and deliver a 300kW converter meeting the design criteria specified. Dr. Rudy Limpaecher at SAIC and Dr. Tony Mavretic at Siat of Boston Inc. will consult on the project. We already have outside investment groups interested in investing in the Phase III manufacturing effort.