High-Power Integrated Magnetics for Automotive Power Converters

October 14, 2018 by Paul Shepard

PREMO has announced the 3DP-Series including the 3kW_HVLV (the 3DP-3KWHVLV-001 Full Bridge LLC Transformer 950 µH + Resonant Choke 21 µH + Parallel Inductor 50 µH is pictured above) & 7kW_HVHV (Full Bridge LLC Transformer 160 µH + Resonant Choke 13 µH) Transformer + Chokes, providing up to 40-50% reduction in volume compared with current discrete industrial solutions for the same power management. Other topologies and powers are under design (11kW and 22kW).

PREMO has been investing in innovative inductive components design applying 3DPower™ concept coming from our large experience in 3D-magnetic sensors using in LF (low frequency) for RFID applications.

Once electromagnetic performance is reached, internal and external thermal links are the most important question to solve in the design if these 3D-Power™ components: "Heat Dissipation".

Thermal behavior has been solved using thermal conductive plastics on the bobbins to create a thermal link between the wire and the core: thermal pad or thermal liquid gap filling material, thermal liquid gap filler dispensed to guarantee reliable thermal link between bobbins, windings and core. Core adhesive is also a key from the MTBF point of view (core cracks due to temperature gradient between heat and cold halve) producing a big or low thermal resistance.

Most of the power converters (resonant topologies) in the market have a transformer, resonant choke and output choke. Every component has their own design, core, winding and thermal dissipation solution.

3DP-7KWHVHV-001: Full Bridge LLC Transformer 160 µH + Resonant Choke 13 µH

3DPower™ provides a unique solution just in one single component.  This is a significant advantage starting at the beginning of the value chain:

  • Power converter design with one inductive component in mind
  • One mechanical drawing interface to fit and connect
  • Improvement of MTBF
  • Important volume and weight reduction (-40 to -50%).
  • Energy efficiency & cost effective
  • Carbon footprint reduction worldwide (energy reduction to produce magnetic cores)

The 3DP-componetns typically meet the AEC-Q200 (specific automotive quality standard) and other more restrictive customer automotive supplier standards. Samples available in our web page by end of Q4.

This innovation is based on several patents since 2016 and has been designed to reach some objectives such as increase power density (decreasing power magnetic required volume), combine 2 or 3 components in one (saving magnetic cores) and reduce weight, so finally in a cost-effective solution demanded by automotive sector.

Engineers will be able to see (under invitation) PREMO's recent innovations at electronica Munich, Hall B6 / Booth 318, Hall B3 Booth 548.