Design of high-density dc/dc converters

Zero- Voltage-Switching Multi-Resonant-Converter (ZVS-MRC) techniques are applied with hybrid microelectronics fabrication technologies to design and implement efficient, high-density (>50 W/in³) dc/dc converters.

A low-profile high-density power stage of a 25 W dc/dc flyback ZVS-MRC is designed and built, and experimental results are shown. A high-density control circuit for a 50 W forward ZVS-MRC is designed using an integrated controller. This circuit is implemented into the high-density power stage previously designed by Tabisz and Lee to attain an overall converter power density of above 80 W/in³. A low-profile interleaved winding structure, fabricated by laminating copper-on-polyamide, for the transformer in the 50 W ZVS-MRC is introduced. Finite element analysis is performed to show the advantages gained with this structure.