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A High Frequency 40kW Step-Up Converter for Fuel Cell Electrical Vehicles Based on SiC MOSFET

With the development of fuel cell electrical vehicles, a class of step-up DC-DC converters with high efficiency, high power density and low input current ripple is needed. For this application, a high frequency 40kW DC-DC converter is proposed in this paper. By using SiC MOSFETs, operating frequency of the converter is up to 100 kHz, thus reducing the volume and weight of inductors and capacitors. Besides, the power loss is reduced effectively by replacing the diode in boost circuit by a SiC MOSFET. Meanwhile, the interleaved 6 half-bridge power modules achieve much smaller input current ripple than that of single channel circuit. The parameter design and power losses distribution and optimization are analysis in this paper. Finally, a natural cooling prototype converter was built, the power density is about 62W/in3, and experiment results show that current ripples are less than 10%, and efficiency is about 98.4% at rated power.