%0 Journal Article %1 9658121 %A Weimer, Julian %A Koch, Dominik %A Nitzsche, Maximilian %A Haarer, Jörg %A Roth-Stielow, Jörg %A Kallfass, Ingmar %D 2022 %J IEEE Open Journal of Power Electronics %K haarer ilea nitzsche roth-stielow %P 13-25 %T Miniaturization and Thermal Design of a 170 W AC/DC Battery Charger Utilizing GaN Power Devices %U https://ieeexplore.ieee.org/document/9658121 %V 3 %X This paper presents the design and analysis of a high-density two-stage battery charger for mid-power applications like small electric vehicles and high-performance laptops utilizing gallium nitride (GaN) power devices. In addition to adherence of maximum junction temperatures, a thermal analysis is carried out for in-housing operation, which is particularly critical for fanless wall chargers. Design measures include calorimetric semiconductor selection, half-bridge miniaturization, thermally conductive epoxy resin and reference-based convection modeling for thermally optimized component placement using 3D-stacking. Furthermore, the remaining optimization potential of the charger is estimated by virtual prototyping. A 170 W hardware prototype is developed and tested, achieving a two-stage power section efficiency of 95.4% with a maximum switching frequency of 550 kHz. This results in a power density in open-housing operation of 1.6 kW/dm<inline-formula><tex-math notation="LaTeX">$^3$</tex-math></inline-formula>. Using epoxy resin, copper and graphite heat spreaders, an in-housing operation power density of 1.1 kW/dm<inline-formula><tex-math notation="LaTeX">$^3$</tex-math></inline-formula> is achieved with minor reduction of output power due to surface temperature constraints.

@article{9658121, abstract = {This paper presents the design and analysis of a high-density two-stage battery charger for mid-power applications like small electric vehicles and high-performance laptops utilizing gallium nitride (GaN) power devices. In addition to adherence of maximum junction temperatures, a thermal analysis is carried out for in-housing operation, which is particularly critical for fanless wall chargers. Design measures include calorimetric semiconductor selection, half-bridge miniaturization, thermally conductive epoxy resin and reference-based convection modeling for thermally optimized component placement using 3D-stacking. Furthermore, the remaining optimization potential of the charger is estimated by virtual prototyping. A 170 W hardware prototype is developed and tested, achieving a two-stage power section efficiency of 95.4% with a maximum switching frequency of 550 kHz. This results in a power density in open-housing operation of 1.6 kW/dm<inline-formula><tex-math notation="LaTeX">$^{3}$</tex-math></inline-formula>. Using epoxy resin, copper and graphite heat spreaders, an in-housing operation power density of 1.1 kW/dm<inline-formula><tex-math notation="LaTeX">$^{3}$</tex-math></inline-formula> is achieved with minor reduction of output power due to surface temperature constraints.}, added-at = {2022-01-20T10:17:40.000+0100}, author = {Weimer, Julian and Koch, Dominik and Nitzsche, Maximilian and Haarer, Jörg and Roth-Stielow, Jörg and Kallfass, Ingmar}, biburl = {https://puma.ub.uni-stuttgart.de/bibtex/26f99bced1623856d90ade2e3aa40a2cd/ilea}, description = {Miniaturization and Thermal Design of a 170 W AC/DC Battery Charger Utilizing GaN Power Devices | IEEE Journals & Magazine | IEEE Xplore}, interhash = {fc324eb50d3b2eee7f514c5cf43c809e}, intrahash = {6f99bced1623856d90ade2e3aa40a2cd}, issn = {2644-1314}, journal = {IEEE Open Journal of Power Electronics}, keywords = {haarer ilea nitzsche roth-stielow}, pages = {13-25}, timestamp = {2023-10-12T11:12:21.000+0200}, title = {Miniaturization and Thermal Design of a 170 W AC/DC Battery Charger Utilizing GaN Power Devices}, url = {https://ieeexplore.ieee.org/document/9658121}, volume = 3, year = 2022 }