Design Considerations of a Single Stage LLC Battery Charger

Usually battery chargers have two stages and DC charging current is considered to be necessary for a proper charging. To decrease the charger volume, a single stage LLC battery charger is investigated in this paper. PFC stage is eliminated, therefore no bulky capacitor is necessary any more, and battery is charged with a sinusoidal-like charging current. However, previous studies show that, such a pulsating charging current has only minimal impact on battery life and efficiency. Design considerations of the resonant tank and optimal transformer design are presented. A 360W single stage LLC converter prototype for e-bike charger achieves a power factor of 0.98, efficiency of 0.93 and power density of 1.8kW/dm3.