This paper presents a control technique for flying capacitor multi-level (FCML) converters to achieve zero-voltage switching (ZVS) across the full range of duty cycles, with application in high power density and high efficiency power converters. Previous works have used variable frequency control to enable ZVS at specific duty cycles in FCML converters, but have not been able to use these methods to allow ZVS across the full range. This work uses dynamic level selection and variable frequency control to increase inductor current ripple at duty cycle ranges for which ZVS was previously unattainable. An experimental 5-level FCML prototype has been built using GaN devices on a single-sided PCB to demonstrate this control technique. We demonstrate 4-level and 5-level operation with ZVS at duty cycles that are not possible with 5-level operation alone, as well as a dynamic level transition with active capacitor voltage balancing.

This paper presents a control technique for flying capacitor multi-level (FCML) converters to achieve zero-voltage switching (ZVS) across the full range of duty cycles, with application in high power density and high efficiency power converters. Previous works have used variable frequency control to enable ZVS at specific duty cycles in FCML converters, but have not been able to use these methods to enable ZVS across the full range. This work uses dynamic level selection and variable frequency control to increase inductor current ripple at duty cycle ranges for which ZVS was previously unattainable. An experimental 5-level FCML prototype has been built using GaN devices on a single-sided PCB to demonstrate this control technique. We demonstrate 4-level and 5-level operation with ZVS at duty cycles that are not possible with 5-level operation alone, as well as a dynamic level transition with active capacitor voltage balancing.

This article investigates behavior of flying capacitor multilevel (FCML) converters in single-phase buck-type power factor correction (PFC) applications. Recent developments in FCML converters using gallium nitride (GaN) transistors are leveraged to improve power density of a single-phase 240 \text{V}_{\text{RMS}} ac to direct 48 V dc conversion stage in data center power delivery applications. Here, we experimentally demonstrate this concept in a digitally controlled six-level FCML converter hardware prototype. The experimental prototype can deliver 4.5 A average output current at 48 V, resulting in 216 W output power. A key contribution of this article is experimental demonstration of an FCML buck converter in a single-phase PFC application where the flying capacitor voltages follow fractions of the rectified input voltage by swinging at twice-line frequency.