Three-phase LLC resonant converter with integrated magnetics

Recently, Electric Vehicles (EVs) have required high power density and high efficiency systems in order to save energy and costs. Specifically, in the DC-DC converter that feeds the non-propulsive loads in these vehicles, where the output voltage is much lower than the one of the energy storage unit. Therefore, the output current becomes quite high, and the efficiency and power density are reduced due to the high current ratings. Furthermore, magnetic components usually are the biggest contributors to the mass and volume in these converters. This paper proposes a Three-phase LLC resonant converter with one integrated transformer where all the windings of the three independent transformers are installed into only one core. Using this technique, a high reduction in the core size and thereby an increment in the power density and a reduction of the production cost are obtained. In addition, this integrated transformer is intended to be applied in the novel Three-phase LLC resonant converter with Star connection that is expected to offer reduction of the imbalanced output current, which is produced by tolerances between the phase components. Finally, the proposed converter with the novel integrated transformer is discussed and evaluated from the experimental point of view. As a result, a 70% reduction in the mass of the magnetic cores was achieved.