Abstract: A hybrid double-sided power switch module comprises a double PCB assembly with switch dies and conductive spacers disposed at both sides of the double PCB assembly in different topologies. The gate connections of the switch dies are enhanced by spring pins soldered in the THVs formed through the PCBs in alignment with the gate terminals. MFCs are positioned at both sides of the double PCBs assembly in contact with the tops of the switch dies and conductive spacers with fuzz buttons serving as contacts between the MFCs and the switch dies and spacers. MFCs serve different functions including AC bus-bars, DC bus-bars, heat-sinks, and their combination. The module can withstand external stress and is fabricated by a simplified and inexpensive process requiring only two solder pastes.

Abstract: A hybrid double-sided power switch module comprises a double PCB assembly with switch dies and conductive spacers disposed at both sides of the double PCB assembly in different topologies. The gate connections of the switch dies are enhanced by spring pins soldered in the THVs formed through the PCBs in alignment with the gate terminals. MFCs are positioned at both sides of the double PCBs assembly in contact with the tops of the switch dies and conductive spacers with fuzz buttons serving as contacts between the MFCs and the switch dies and spacers. MFCs serve different functions including AC bus-bars, DC bus-bars, heat-sinks, and their combination. The module can withstand external stress and is fabricated by a simplified and inexpensive process requiring only two solder pastes.

Abstract: Aspects of the disclosure relate to a half-bridge on a monolithic die. In one example, a half-bridge module includes a monolithic die, a high-side transistor integrated in the monolithic die, a low-side transistor integrated in the monolithic die, and a decoupling capacitor integrated in the monolithic die. The decoupling capacitor may be disposed between the high-side transistor and the low-side transistor. Other aspects, embodiments, and features are also claimed and described.

Abstract: In some embodiments, systems and methods for connector assembly for use with an AC or DC power interface of a power conversion device, such as a converter and an inverter, are provided. The connector assembly can include a circuit board, a power connector, and a pin. The power connector can have a base configured to be secured relative to the circuit board and define a first channel extending through the power connector along a first channel axis. The first pin can have a first pin body that extends along a first pin axis and a first connection element that extends along the first pin axis from the first pin body to a first terminal end that is skewed relative to the first pin axis.

Abstract: In some embodiments, systems and methods for connector assembly for use with an AC or DC power interface of a power conversion device, such as a converter and an inverter, are provided. The connector assembly can include a circuit board, a power connector, and a pin. The power connector can have a base configured to be secured relative to the circuit board and define a first channel extending through the power connector along a first channel axis. The first pin can have a first pin body that extends along a first pin axis and a first connection element that extends along the first pin axis from the first pin body to a first terminal end that is skewed relative to the first pin axis.

Abstract: Compact light-weight on-board three-port power electronic system built in various configurations of triple-active-bridge-derived topologies, including modular implementations, with control strategies capable of bi-directional power transfer among the three ports of the power electronic system, including simultaneous charging of a high voltage (HV) battery and a low voltage (LV) battery from a single phase power grid or a three-phase power grid with minimized reactive power and active circulating current, with ensured soft-switching for MOSFET devices, and with enhanced synchronous rectification and reduced power losses.

Abstract: A multi-port power conversion system can have a multi-winding transformer and at least three ports. Each port can be coupled to the multi-winding transformer. Each port can have a semiconductor bridge and a coupling network. For each port, the semiconductor bridge can have two or more levels and can comprise at least two switches. The coupling network for each port can comprise at least one inductor. The semiconductor bridge can be coupled to the multi-winding transformer via the respective coupling network. The multi-port power conversion system can have a multi-active bridge (MAB) architecture that is universally applicable to AC-DC, DC-DC, DC-AC, and AC-AC conversion applications and extendable to any number of ports.

Abstract: A set of multi-winding transformer designs that achieve leakage integration in multi-port power electronics systems is presented. The magnetic design structures are extendable to realize an N-port multi-winding transformer with or without leakage inductance integration, that interfaces different voltage levels (high-voltage and/or low-voltage) with galvanic isolation. The disclosed designs enable: (i) reduced number of discrete magnetic components (ii) high efficiency and high power density; (iii) reduced transformer parasitic capacitances. Furthermore, a global transformer optimization approach that considers magnetizing and leakage inductances, core and winding losses, and parasitic capacitances is presented to systemize the sophisticated multi-winding integrated leakage transformer design process.

Abstract: In some embodiments, systems and methods for connector assembly for use with an AC or DC power interface of a power conversion device, such as a converter and an inverter, are provided. The connector assembly can include a circuit board, a power connector, and a pin. The power connector can have a base configured to be secured relative to the circuit board and define a first channel extending through the power connector along a first channel axis. The first pin can have a first pin body that extends along a first pin axis and a first connection element that extends along the first pin axis from the first pin body to a first terminal end that is skewed relative to the first pin axis.

Abstract: Compact light-weight on-board three-port power electronic system built in various configurations of triple-active-bridge-derived topologies, including modular implementations, with control strategies capable of bi-directional power transfer among the three ports, including simultaneous charging of HV and LV batteries from a single phase or three phase power grid with minimized reactive power and active circulating current, with ensured soft-switching for MOSFET devices, and with enhanced synchronous rectification and reduced power losses.

Abstract: An integrated and isolated onboard charger for plug-in electric vehicles, includes an ac-dc converter and a dual-output dc-dc resonant converter, for both HV traction batteries and LV loads. In addition, the integrated and isolated onboard charger may be configured as unidirectional or bidirectional, and is capable of delivering power from HV traction batteries to the grid for vehicle-to-grid (V2G) applications. To increase the power density of the converter, the dual-output DC-DC resonant converter may combine magnetic components of resonant networks into a single three-winding electromagnetically integrated transformer (EMIT). The resonant converter may be configured as a half-bridge topology with split capacitors as the resonant network components to further reduce the size of converter. The integrated charger may be configured for various operating modes, including grid to vehicle (G2V), vehicle to grid (V2G) and high voltage to low voltage, HV-to-LV (H2L) charging.

Abstract: An onboard charger for both single-phase (level-1 and level-2, up to 19.2 kW) and three-phase (level-3, above 20 kW) charging of a battery in Plug-in Electric Vehicles (PEVs) is integrated with the Propulsion machine-Inverter Group residing in the PEV, and is controlled to operate in propulsion and battery charging modes. The subject integrated onboard charger provides battery charging at the rated power of the Propulsion machine, does not need motor/inverter rearrangement, does not require additional bulk add-on passive components, provides an effective input current ripple cancellation, and operates without rotation of the Propulsion machine during the steady state charging.

Abstract: An AC-to-DC converter includes a multi-resonant switching circuit including an AC-AC stage soft-switched LC network that converts a low-frequency low-amplitude alternating input voltage into a higher-frequency higher-amplitude alternating voltage and an AC-DC stage rectifying the higher-frequency higher-amplitude alternating voltage into a DC output voltage via a soft-switched diode. An AC-to-DC converter system includes at least two multi-resonant switching circuits that include at least two AC-AC stages and an AC-DC stage. A control system for the AC-to-DC converter includes at least two resonant gate drivers that each includes: one MOSFET gate configured to transmit a gate voltage signal to an AC-to-DC converter; an on/off logic module electrically coupled to the MOSFET gate; a resonant tank LC circuit electrically coupled to the on/off logic module; and a voltage bias module electrically coupled to the resonant tank LC circuit.

Abstract: An integrated and isolated onboard charger for plug-in electric vehicles, includes an ac-dc converter and a dual-output dc-dc resonant converter, for both HV traction batteries and LV loads. In addition, the integrated and isolated onboard charger may be configured as unidirectional or bidirectional, and is capable of delivering power from HV traction batteries to the grid for vehicle-to-grid (V2G) applications. To increase the power density of the converter, the dual-output DC-DC resonant converter may combine magnetic components of resonant networks into a single three-winding electromagnetically integrated transformer (EMIT). The resonant converter may be configured as a half-bridge topology with split capacitors as the resonant network components to further reduce the size of converter. The integrated charger may be configured for various operating modes, including grid to vehicle (G2V), vehicle to grid (V2G) and high voltage to low voltage, HV-to-LV (H2L) charging.

Abstract: An integrated and isolated onboard charger for plug-in electric vehicles, includes an ac-dc converter and a dual-output dc-dc resonant converter, for both HV traction batteries and LV loads. In addition, the integrated and isolated onboard charger may be configured as unidirectional or bidirectional, and is capable of delivering power from HV traction batteries to the grid for vehicle-to-grid (V2G) applications. To increase the power density of the converter, the dual-output DC-DC resonant converter may combine magnetic components of resonant networks into a single three-winding electromagnetically integrated transformer (EMIT). The resonant converter may be configured as a half-bridge topology with split capacitors as the resonant network components to further reduce the size of converter. The integrated charger may be configured for various operating modes, including grid to vehicle (G2V), vehicle to grid (V2G) and high voltage to low voltage, HV-to-LV (H2L) charging.

Abstract: A powertrain system for plug-in electric vehicles (PEVs) includes one or a number of Energy Storage Sub-Systems (ESSs), and a plurality of Propulsion Machine-Inverter Groups, operatively coupled to the ESSs for being powered in accordance with power requirements of the Propulsion Machines (PMs). Various interface configurations between the ESS(s) and Propulsion Machines are contemplated for the subject powertrain. Some ESSs are coupled to respective PMs (via a common DC Link or a number of independent DC Links) directly, and some through power converters, which may be DC-to-DC, DC-to-AC, AC-to-DC, bi-directional, single input-single output, multiple input-single output, or multiple input-multiple output converters.

Abstract: The bi-directional DC/DC converter has zero voltage switching (ZVS) soft switching capability resulting in a higher efficiency, and provides reduction of the switching losses due to higher switching frequencies. The capability of operation in higher frequencies results in reducing the size of passive components including inductance and capacitors. The subject DC/DC converter is capable of operating with three voltage levels in both power flow directions, thus providing flexibility in the voltage control and attaining lower inductor current ripple and lower switch voltage ratings. DC link capacitors are replaced with ultra capacitor banks split in two.

Abstract: An AC-to-DC converter includes a multi-resonant switching circuit including an AC-AC stage soft-switched LC network that converts a low-frequency low-amplitude alternating input voltage into a higher-frequency higher-amplitude alternating voltage and an AC-DC stage rectifying the higher-frequency higher-amplitude alternating voltage into a DC output voltage via a soft-switched diode. An AC-to-DC converter system includes at least two multi-resonant switching circuits that include at least two AC-AC stages and an AC-DC stage. A control system for the AC-to-DC converter includes at least two resonant gate drivers that each includes: one MOSFET gate configured to transmit a gate voltage signal to an AC-to-DC converter; an on/off logic module electrically coupled to the MOSFET gate; a resonant tank LC circuit electrically coupled to the on/off logic module; and a voltage bias module electrically coupled to the resonant tank LC circuit.

Abstract: An integrated and isolated onboard charger for plug-in electric vehicles, includes an ac-dc converter and a dual-output dc-dc resonant converter, for both HV traction batteries and LV loads. In addition, the integrated and isolated onboard charger may be configured as unidirectional or bidirectional, and is capable of delivering power from HV traction batteries to the grid for vehicle-to-grid (V2G) applications. To increase the power density of the converter, the dual-output DC-DC resonant converter may combine magnetic components of resonant networks into a single three-winding electromagnetically integrated transformer (EMIT). The resonant converter may be configured as a half-bridge topology with split capacitors as the resonant network components to further reduce the size of converter. The integrated charger may be configured for various operating modes, including grid to vehicle (G2V), vehicle to grid (V2G) and high voltage to low voltage, HV-to-LV (H2L) charging.

Abstract: A multiple-input DC-DC converter that is capable of power diversification among different energy sources with different voltage-current characteristics. The converter is capable of bidirectional operation in buck, boost and buck-boost modes and provides a positive output voltage without the need for a transformer.