Designing a High Frequency 5 KW DC-DC Converter

This paper describes the design of a DC-DC Converter System which utilizes a high frequency 20 KHz switching circuit to perform power conversion, and which provides a voltage and current regulated DC output. The converter system as described, is capable of delivering up to 5 KW of isolated DC power to a prescribed load. The paper describes pulse width modulated drive methods, power amplifier design, and regulation and control methods as well as discussing thermal design considerations and techniques, and circuit layout considerations used to minimize lead inductances for optimum circuit performance.