Premo has developed an 11 kW power converter using its patented technology that integrates multiple magnetic components (writes Nick Flaherty).

The 3DP-11KWHVHV combines a full-bridge 150 µH LLC resonant transformer and 25 µH resonant choke in a single unit. This cuts the volume of the converter by up to half, and can reduce the amount of ferrite material required by two-thirds.

Most power converters based on resonant topologies use a separate transformer, resonant choke and output choke. Every component has its own design, core, winding and thermal dissipation solution. When power levels exceed 7 kW, heat dissipation is a key consideration.

Premo’s 3DPower approach integrates two magnetics components that share the same core and feature two orthogonal magnetic fields at all points within the core. That means there is only one inductive component to consider and one mechanical drawing interface to fit and connect, increasing the reliability.

3Dpower uses CoolMag, a silicon compound compatible with the magnetics that dissipates the heat from the top of the magnetics to the liquid-cooling plate with a thermal conductivity greater than 1.7 W/mK. The silicon compound removes the air from the coils to improve the heat dissipation. 

The 3DP-11KWHVHV is available with an aluminium heat sink that acts as a direct thermal interface to the cold plate, and Premo is developing a 22 kW version. Designs can be fully customised according to customer requirements.

It meets the AEC-Q200 automotive quality standard and other, more restrictive customer automotive supplier standards.