Towards a 30 kW/liter, Three-Phase Unity Power Factor Rectifier

In this paper, a forced air-cooled, 400 kHz, 10 kW Vienna rectifier with a power density of 8.5 kW/liter is presented. To further improve the power density, the switching frequency is increased to reduce the EMI filter volume. A design for an 18.5 kW/liter, 2.5 MHz rectifier is proposed. By using today's technology, it is calculated that the maximum power density for a forced air-cooled and water-cooled rectifier is 20.8 kW/liter and 24 kW/liter respectively. To achieve 30 kW/liter, improvements must be made in passive component material properties, reducing semiconductor losses and improving the cooling system.

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