An On-Board Charger (OBC) is built into Electric Vehicles (EVs) and Plug-in Hybrid Electric Vehicles (PHEVs) to convert AC power from home or public charging stations into DC power for the battery. Typical OBC power output ranges from 3.6 kW to 22 kW, enabling efficient charging in various environments.

Battery capacity varies by vehicle type—whether compact cars, SUVs, or sports models—and On-Board Charger (OBC) power output is generally designed to fully charge a battery in about eight hours, though regional standards may differ. As electric vehicles become more common and battery sizes increase, high-output OBCs are essential to meet market expectations for faster charging and more efficient systems. To achieve this, OBC components must provide high voltage tolerance, large current capacity, low power loss, strong heat resistance, and a compact design.

Voltage Measuring Circuits monitor input and output voltage to control the conversion process. These circuits typically measure voltage across resistors connected in series, using high-precision chip resistors with thin-film structures for minimal tolerance and low TCR, enabling accurate control of output characteristics.

Noise Filters located at both input and output stages, suppress internal and external interference to prevent malfunctions. They generally combine large inductors with film capacitors, which offer high reliability, resistance to humidity and thermal impact, and built-in safety mechanisms that open the circuit in failure mode.

Full-Wave Rectifying and PFC Circuits convert AC voltage into DC and improve power efficiency by correcting phase shifts during rectification. These circuits rely on film capacitors and coils for voltage smoothing and stability, ensuring efficient power delivery.

Voltage Conversion Circuits adjust voltage through switching elements and transformers. Because switching actions can create noise, resistors are added to gate terminals to reduce interference. Compact, high-power chip resistors are commonly used to support these operations while minimizing circuit size.

DC/DC Converters supply power to the control circuit and stabilize voltage output. They use conductive polymer hybrid aluminum electrolytic capacitors to eliminate noise and smooth voltage, along with automotive power inductors that handle large currents efficiently while reducing power loss.

Communication Interface connects the OBC to external systems such as CAN or Ethernet. To protect against electrostatic discharge and maintain signal integrity, chip varistors are integrated into the transceiver circuit, offering a wide range of capacitance characteristics for reliable communication at various speeds.

 

On-Board Chargers are the backbone of efficient electric vehicle charging, transforming AC power into the precise DC voltage required for modern batteries. As EV adoption accelerates and battery capacities increase, the demand for high-output OBCs and advanced electronic components will continue to rise. Meeting these challenges requires solutions that deliver high voltage tolerance, large current capacity, low power loss, heat resistance, and compact design—all while ensuring safety and reliability.

Through continuous innovation and the use of advanced materials, Panasonic Industry provides components that enable OBC systems to perform at their best. These technologies support the evolution of electric mobility, helping to pave the way for a more sustainable future.