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Circuit Design Implementation
60 V-to-35 kV Input-Parallel Output-Series DC-DCConverter Using Multi-Level Class-DE Rectifiers
Sanghyeon Park*, Lei Gu*, and Juan Rivas-Davila* Sanghyeon Park and Lei Gu made an equal contribution to this work.
Stanford University Power Electronics Research (SUPER) Lab
Project GoalTo develop a small-sized lightweight
dc-dc converter for high-voltage low-
current applications (10-100s kV and
1-100 mA) such as electrostatic
precipitation, milk pasteurization or
X-ray / neutron beam generation.
Class-DE Rectifier
300V
+
(a)
Cb
Cb D
D
(d)
k
20-Stage
Rectifiers
k
20-Stage
Rectifiers
k
20-Stage
Rectifiers
6 kV
+
6 kV
+
6 kV
+
36 kV
+
Full-Bridge Inverters
Cs
Cs
Cs
Cs
Cs
Cs
Lp
Ls
Lp
Ls
Lp
Ls
VDD = 60 V
Experimental Results60V-to-6kV dc-dc converter,single unit
60V-to-35kV dc-dc converter,6 units stacked
60V-to-6kV dc-dc converter, single unit
60V-to-35kV dc-dc converter, 6 units stacked
• Switching frequency = 1.25 MHz
• Input voltage = 60 V
• Output voltage = 6 kV
• Output current = 6 mA
• DC-to-DC efficiency = 81 %
• Rise time = 200 μs
• Output voltage waveform
- horizontal: 500 us/div
- vertical: 6 kV/div (3:1 attenuated in the fig.)
• Switching frequency = 1.25 MHz
• Input voltage = 60 V
• Output voltage = 35 kV
• Output current = 5.83 mA
• DC-to-DC efficiency = 73 %
• Rise time = 296 μs
• Power density = 5.1 W/in3
• Specific power = 1.1 W/g
• Thermal image after 3 minutes of
continuous operation (6 kV, 6 mA output)
• Dimension (L×W×H) = 8 in × 2.5 in × 2 in
(20 cm × 6 cm × 5 cm)
20-Stage
Class-DE
Rectifiers,
6 kVdc output
Planar air-core
PCB transformer1.25 MHz
full-bridge
inverter,
60 Vdc input
Kapton films
for dc isolation
Batteries for scale
Batteries for scale
1st level converter
2nd level converter
6th level converter
Motivation
Transformer: 155 ◦C
Ambient: 23 ◦C
IEEE APEC 2018, San Antonio, TX, March 8, 2018
• Many emerging applications can benefit
from a compact high-voltage power supply.
- miniaturized electrostatic precipitator(Talukder, Park, & Rivas, 2017)
• Existing technologies are often too bulky
and heavy for small scale applications.
Six inverters
connected in
parallelSix rectifiers
connected in
series
Transformers
providing dc
isolation
• Weight = 188 g
• Lateral view
ESP off ESP on
- portable milk pasteurizer(Raymond, Liang, Gu, & Rivas, 2015)
300V+
Vout = 6 kV
+
20-Stage Class-DE Rectifiers
CBb,20
CBb,21
CBt,20
300V+
CBt,n+1
300V+
CBb,n
CBt,n
CBb,n+1
CBb,1
CBt,1
300V+
