Duration: 2004 - 2007

Develop know-how for design of compact power electronic converters, by exploiting advances within essential key technologies like power electronics, material technology, cooling technology and design methodology. The development know-how is to be used to demonstrate a minimum of 20 % total cost saving potential of investment and operation cost related to converters up to 10 kW.

Sub-goals

• Demonstrate new, cost efficient technology for converter cooling
• Demonstrate new design for significant reduction in space and weight demand
• Expose possibilities for exploitation of advances in material technology
• Results are to be worth publishing internationally

Overall design challenges

• Satisfactory operating reliability
• Satisfactory accessibility for condition control and repair
• Adaptation to space limitations
• Acceptable costs

Plan for “Integration level 1” (September  2006)

Primary goals:

• Realization of a 750 W converter unit with PFC input stage and 1 MHz DC/DC isolated (transformer) output stage
• Efficiency above 90 %
• Most of the magnetic components realized as planar components with integrated windings on circuit board
• Resonance inductor (resonance or quasi resonance topology) realized as leakage inductor in the hf-transformer (I MHz)
• Integrated heat spreaders/ thermal conductors

Secondary goals:

• Surface mounted switching transistors
• Main focus on the 1 MHz DC/DC stage
• Main focus on planar components for the DC/DC-transformer with integrated resonance inductor
• Adapted driver circuit
• Topology utilizing parasitic capacitances in transistors, laminate etc.
• Integrated current sensors in L and  T
• Potential for low production costs and big volumes

Challenges for integrated design: