Capacitorless Power Electronics Converters Using Integrated Planar Electro-Magnetics

Abstract

The short lifespan of capacitors in power electronics converters is a significant challenge. These capacitors, often electrolytic, are vital for voltage smoothing and frequency filtering. However, their susceptibility to heat, ripple current, and aging can lead to premature faults. This can cause issues like output voltage instability and short circuits, ultimately resulting in catastrophic failure and system shutdown. Capacitors are responsible for 30% of power electronics failures. To tackle this challenge, scientists, researchers, and engineers are exploring various approaches detailed in technical literature. These include exploring alternative capacitor technologies, implementing active and passive cooling solutions, and developing advanced monitoring techniques to predict and prevent failures. However, these solutions often come with drawbacks such as increased complexity, reduced efficiency, or higher upfront costs. Additionally, research in material science is ongoing to develop corrosion-resistant capacitors, but such devices are not readily available. This dissertation presents a capacitorless solution for dc-dc and dc-ac converters. The proposed solution involves harnessing parasitic elements and integrating them as intrinsic components in power converter technology. This approach holds the promise of enhancing power electronics reliability ratings, thereby facilitating breakthroughs in electric vehicles, compact power processing units, and renewable energy systems. The central scientific premise of this proposal is that the capacitance requirement in a power converter can be met by deliberately augmenting parasitic components. Our research hypothesis that incorporating high dielectric material-based thin-films, fabricated using nanotechnology, into planar magnetics will enable the development of a family of capacitorless electronic converters that do not rely on discrete capacitors. This innovative approach represents a departure from the traditional power converter schemes employed in industry. The first family of converters introduces a novel capacitorless solid-state power filter (SSPF) for single-phase dc-ac converters. The proposed configuration, comprising a planar transformer and an H-bridge converter operating at high frequency, generates sinusoidal ac voltage without relying on capacitors. Another innovative dc-ac inverter design is the twelve step six-level inverter, which does not incorporate capacitors in its structure. The second family of capacitorless topologies consists of non-isolated dc-dc converters, namely the buck converter and the buck-boost converter. These converters utilize alternative materials with high dielectric constants, such as calcium copper titanate (CCTO), to intentionally enhance specific parasitic components, notably inter capacitance. This innovative approach reduces reliance on external discrete capacitors and facilitates the development of highly reliable converters. The study also includes detailed discussions on the necessary design specifications for these parasitic capacitors. Furthermore, comprehensive finite element analysis solutions and detailed circuit models are provided. A design example is presented to demonstrate the practical application of the proposed concept in electric vehicle (EV) low voltage side dc-dc power converters used to supply EVs low voltage loads.