2200A/48V-to-1V Low-Profile Direct Power Converter with standard PCB transformer

This article introduces a 48V-1V high-current single-stage power converter for high performance applications. A hardware prototype is designed and built by stacking four 12:1V modules, with the primary stacks connected in series and the secondary side in parallel. This configuration provides voltage balance in the primary stacks and intrinsic current sharing between the secondary cells. The Segmented Winding Transformer is designed to achieve a 5mm height; a Planar Matrix Transformer with custom magnetic cores is implemented on a standard 3oz PCB, ensuring repeatability and simplifying manufacturing. A significant characteristic of this power converter is the high efficiency achieved, exceeding 90% for currents from 200A to 2000A, with a peak efficiency of 93.6% at 500A, including driving losses. By modifying the primary side, the power converter offers fast dynamic response and output voltage regulation, achieved through low leakage inductance and high voltage in the transformer. With a current slope exceeding 3000A/μs and interleaved phases, the power converter can handle a 440A load step with minimal output voltage deviation.