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PTCEL PTC
Thermistors
SQW61N65EF-GE3
Automotive E Series
Power MOSFETs
MKP385eTHB AC &
Pulse Metallized Film
Capacitors
VS-40TPS12LHM3 High-
Voltage Thyristor, Phase
Control SCR, 40 A
VS-E5PH6012LHN3
Hyperfast Rectifier, 60
A FRED Pt
®
G5
avoid an imbalance in the DC bus. An important component in the
LLC converter is the resonant capacitor (C5 and C15 in Figure 4)
because it must handle high peak voltages, large ripple currents,
and high di/dt.
Using a single film capacitor for this function is usually not
possible because of the ripple current requirement, so multiple
capacitors connected in parallel are usually required. In this
case, the Vishay MKP385e series of high-voltage resonant
capacitors was used; seven 15nF/2000V capacitors in parallel
to handle the 35A
RMS
. The output of the main DC/DC converter
(both stages) must be rectified to provide a DC voltage
for the charging of the battery pack. A full-bridge rectifier
configuration is used for each stage of the converter. The Vishay
VS-E5PX7506LHN3 was used for each diode in the bridge (D7-
D10 in Figure 4 in the positive stage, D11-D14 in Figure 4 in
the negative stage) because they are optimized for low-voltage
drop at the peak sinusoidal current and low reverse-recovery
energy at the resonant frequencies involved. In this application,
the VS-E5PX7506LHN3 provides high-efficiency performance
under all operating conditions, with a maximum efficiency of
~96.7 percent at 400V
AC
input and 500V/45A output (and coolant
temperature at 60°C).
In terms of the mechanical design, a liquid-cooled cold plate is
sandwiched between the power factor correction (PFC) board
and the main DC/DC board on the other side. The TO-247 power
devices (MOSFETs, diodes, thyristors) are all secured to the cold
plate with screws and Kapton film for the insulation barrier.
A discrete OBC design has been presented that is capable of
operating up to 22kW with a 3-phase AC input. It utilizes a cost-
effective topology that can still provide operating efficiencies up
to nearly 97 percent. ▼
VS-E5PX7506LHN3
Hyperfast Rectifier, 75
A FRED Pt
®
G5
