Advanced Manufactured High Frequency Link Transformers for Next Generation Grid-tied Energy Storage Power Conversion Systems

a. Advanced Manufactured High Frequency Link Transformers for Next Generation Grid-tied Energy Storage Power Conversion Systems To date, energy storage systems employ line frequency transformers for voltage matching at the point of common coupling and galvanic isolation. However, these transformers can have a large footprint, lossy, noisy, and heavy, which can limit high density power conversion designs. Recently, there has been interest in high-frequency link converters to reduce the size of the transformer. The magnetic cores utilized in such systems are critical for proper operation and when paired with wide bandgap semiconductors can become the bottleneck for high power throughput, particularly given the limitations of the current available materials. Additionally, even with the significantly lower inductance requirements at high frequency, the current materials demand that the transformer take up a disproportionately large piece of the power electronics footprint (especially if the power electronics design dictates that they be passively cooled) and cost. Added flexibility and agility in PCS design and deployment could be realized through advanced manufactured transformer and inductor cores. Additively manufactured (AM) or 3D printed cores could be fabricated directly onto printed circuit boards (PCBs) and eliminate pick and place power electronics assembly. Manufacturing could be further streamlined through the additive manufacture of the windings in addition to the magnetic core. Applications are sought to demonstrate an additively manufactured high frequency ( 100 kHz) transformer (complete with AM windings) for dual active bridge converter topology rated at > 10 kW, 48 Vdc input and > 300 Vdc output to ultimately further the power density of next generation 3-phase 480/208 Vac PCS. The transformer should be capable of operating at temperatures of 150 C. The final design should show a significant increase in performance, cost reduction, and decrease in footprint compared to a traditional grid-tied power conversion design connected to line frequency transformer. Questions Contact: Imre Gyuk, imre.gyuk@hq.doe.gov