All Case StudiesEV/Automotive
22kW Onboard Charger
Power
22kW
Result
35% size reduction
Industry
EV/Automotive
OF
The Challenge
An EV startup was developing a 22kW three-phase onboard charger for their premium vehicle platform. The allocated packaging volume was 30% smaller than competitor solutions, requiring aggressive power density targets. The OBC also needed to integrate seamlessly with the vehicle's liquid cooling system while meeting automotive EMC requirements.
Our Approach
- Designed compact Vienna rectifier topology with interleaved DC-DC stage
- Selected latest-generation SiC devices for high-frequency operation
- Optimized PCB layout for minimal parasitic inductance and EMI
- Designed integrated liquid-cooled housing with direct FET cooling
- Implemented multi-layer EMI filtering for CISPR 25 compliance
- Validated thermal and EMC performance through HALT testing
Results
35%
Size Reduction
Compared to previous design
4.2 kW/L
Power Density
Industry-leading density
95.5%
Efficiency
At 22kW output