Advanced Energy Rolls Out 1100 W PFC Module in Half-Brick Form Factor

Advanced Energy has announced a 1100 W board-mounted power factor correction (PFC) module, marking a significant milestone in miniaturization for power electronics. The company claims the AIH03ZPFC as the industry’s first solution to deliver this level of continuous power within a standard half-brick form factor.

By offering high levels of thermal performance and power density, the new module provides engineers with a highly efficient solution tailored for industrial, medical, defense, and telecommunications systems where physical space is at a premium.

High Efficiency and Power Density

The AIH03ZPFC features a regulated, non-isolated 390 VDC nominal output that can be adjusted between 350 VDC and 420 VDC. A primary advancement of this module is its ability to achieve a peak efficiency of up to 97.3 percent. This represents a 2.3 percent efficiency improvement over the company’s previous-generation PFC products and translates to a 46 percent reduction in overall power losses.

The 1100 W AIH03ZPFC PFC module provides a peak efficiency of 97.3 percent.

This improved electrical efficiency directly impacts the power density of the assembly. Delivering 380 W/in³—a 44 percent increase compared to prior designs—the module allows power system designers to output higher continuous power without increasing the physical footprint of their converter assemblies.

The encapsulated half-brick measures just 2.4 by 2.3 inches with a low-profile installed height of 0.52 inches, giving engineers the flexibility to maximize usable power in strict dimensional constraints. More information is available in the AIH03ZPFC data sheet.

Integrated Control and Input Flexibility

In addition to its thermal and power capabilities, the AIH03ZPFC introduces features rarely integrated into standard half-brick formats. The module includes internal inrush current limiting and fully digital PMBus control and monitoring. Auxiliary power support is also built-in, enabling external housekeeping functions while keeping the overall system footprint compact and reducing the need for sprawling external circuitry.

The module maintains a unity power factor across a wide input voltage range of 85 to 264 VAC. Crucially, the hardware experiences no power derating under low-input-voltage conditions. This consistent performance simplifies regulatory compliance requirements and ensures robust, reliable performance across varied global grid conditions and transient power states.

Thermal Management and System Integration

Operating efficiently in demanding environments requires a predictable thermal management strategy. The AIH03ZPFC utilizes baseplate contact cooling, which supports continuous operation in baseplate temperatures ranging from -20°C to 100°C, alongside a cold-startup capability in environments as low as -40°C. The module is fully drop-in compatible with standard heatsinks and thermal management solutions.

YouTube video about the AIH03ZPFC module

Engineers can deploy the device as a standalone PFC or seamlessly pair it with downstream DC-DC converters. Integrating digital control, onboard monitoring, and critical protection features into a standardized half-brick footprint helps automotive and industrial design teams avoid complex external circuit designs. This allows original equipment manufacturers to accelerate their time-to-market while utilizing proven, high-density manufacturing standards.

Looking ahead, this hardware seems well suited for high-reliability systems where peak efficiency, thermal flexibility, and minimal footprint are essential. The AIH03ZPFC provides an immediate upgrade path for power system engineers looking to maximize power density while shedding excess volumetric weight and cooling demands.

All images used courtesy of Advanced Energy.