Electric vehicle charger with printed circuit board magnetic components

An 800 Watt portable battery charger for electric vehicles is built using a single four-layer printed circuit board for interconnection all of the power components and to form the magnetic component windings which comprise the EMI filter, a high power factor boost rectifier and a series resonant inverter. Low profile planar E-cores are inserted through slots in the PCB to complete the magnetic components. The design and performance of each magnetic device is examined.