The rapid proliferation of electric vehicles (EVs) has intensified requirements for compact, high-efficiency, and grid-friendly battery chargers. Conventional charger architectures typically employ a discrete boost power-factor-correction (PFC) front-end followed by an isolated DC–DC stage, leading to increased component count, higher losses, and larger magnetic and filter requirements. This paper presents a modified bridgeless boost converter topology that seamlessly integrates active PFC with the DC–DC conversion required for EV battery charging. By employing synchronous SiC MOSFETs in both boost and rectification legs, combined with an interleaved dual-phase design, the proposed charger minimizes conduction and switching losses, reduces input current ripple, and eliminates two diode bridges from the power path.

A 3.3 kW laboratory prototype was developed using planar coupled inductors and a TI C2000 microcontroller implementing a dual-loop control strategy: an inner current-shaping loop for near-unity power factor and an outer voltage regulation loop for battery charging. Experimental evaluation under IEC 61000-3-2 compliance conditions demonstrates a power factor exceeding 0.99, total harmonic distortion below 5 %, and a peak efficiency of 97.2 % over 50 %–100 % load range. The unified PFC/DC–DC approach achieves a 30 % reduction in passive component volume compared to traditional two-stage designs, while thermal tests confirm stable operation under extended load and ambient temperature variations.

These results highlight the converter’s potential for next-generation EV chargers, offering a pathway to reduced system size, lower cost, and enhanced grid compatibility without sacrificing performance or reliability.