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In the no-load condition, LLC converter usually fails to regulate its output voltage although it operates at a high switching frequency. Till now, it is hard to obtain the exact relationship between design parameters and the maximum switching frequency for no-load regulation capability. In this paper, a specific criterion for no-load regulation of LLC converter is provided, without using active components or other modulation schemes. By analyzing the macroscopic switching period and microscopic switching transition in the no-load condition, it is shown that not only the peaking resonant current during the switching transition, but also the resonant tank design affect the no-load regulation of the LLC converter, which affects the no-load regulation capability. Furthermore, the relationship among design parameters is analyzed and the design guideline is also provided to achieve no-load regulation at the specified maximum switching frequency. To verify the effectiveness of the proposed design, 400 V input and 50 V/200 W output prototype is built and tested.

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This paper presents a modified power factor correction (PFC) ON/OFF control and three-dimensional (3D) printed circuit board (PCB) design for a high-efficiency and high-power density onboard charger (OBC). By alternately operating one of two boost modules of the PFC stage at a 50% or less load condition, the proposed PFC control can reduce the load-independent power loss of the PFC stage, such as core loss and capacitor charging loss of switches. It enables OBCs to have high efficiency across a wide output power range and better thermal performance. The 3D-PCB design decouples a trade-off relationship of the PCB trace design and heat spreader design, increasing the power density of OBCs. A 3.3 kW prototype composed of an interleaved totem-pole bridgeless boost PFC converter and full-bridge (FB) LLC converter has been built and tested to verify the proposed PFC control and 3D-PCB effectiveness design. The prototype has 95.7% full power efficiency (98.2% PFC stage efficiency) and 52 W/in3 power density.