Abstract: In at least one embodiment, a power conversion device for a vehicle is provided. The power conversion device includes a transformer, a microcontroller, and a control circuit. The microcontroller is configured to operate at a first frequency to receive a first current signal indicative of a current of a first voltage network and to generate a first envelope control signal in response to the first current signal. The controller is configured to selectively switch a first plurality of switches on a primary side and a second plurality of switches on a secondary side to convert a first input signal into first output signal in response to at least the first envelope control signal. The controller is further configured to selectively switch the first plurality of switches and the second plurality of switches at a second frequency that is greater than the first frequency.

Abstract: An on-board charger for charging a battery, such as a traction battery of an electric vehicle, includes an AC/DC converter and a pulsating buffer (PB) converter. The AC/DC converter is configured to convert an AC input from a mains supply into an output having a DC voltage and a current ripple. The PB converter is connected to the AC/DC converter and is configured to process the output of the AC/DC converter to reduce or minimize the current ripple thereof and transform the output of the AC/DC converter into a battery-level DC output for charging the battery.

Abstract: In at least one embodiment, a power conversion device for a vehicle is provided. The power conversion device includes a transformer, a microcontroller, and a control circuit. The microcontroller is configured to operate at a first frequency to receive a first current signal indicative of a current of a first voltage network and to generate a first envelope control signal in response to the first current signal. The controller is configured to selectively switch a first plurality of switches on a primary side and a second plurality of switches on a secondary side to convert a first input signal into first output signal in response to at least the first envelope control signal. The controller is further configured to selectively switch the first plurality of switches and the second plurality of switches at a second frequency that is greater than the first frequency.

Abstract: An on-board charger for charging a battery, such as a traction battery of an electric vehicle, includes an AC/DC converter and a pulsating buffer (PB) converter. The AC/DC converter is configured to convert an AC input from a mains supply into an output having a DC voltage and a current ripple. The PB converter is connected to the AC/DC converter and is configured to process the output of the AC/DC converter to reduce or minimize the current ripple thereof and transform the output of the AC/DC converter into a battery-level DC output for charging the battery.

Abstract: In at least one embodiment, a transformer assembly is provided. The assembly includes a first printed circuit board (PCB), a magnetic core, a primary winding, and a secondary winding. The magnetic core is positioned about the first PCB. The primary winding is implemented as a wire assembly and is positioned on a first side of the PCB to interface with the magnetic core. The secondary winding is embedded within the first PCB to interface with the primary winding and the magnetic core to convert an input signal into a converted output signal.