A planar integrated RCD snubber/voltage clamp

In order to reduce the cost, size, and weight of power electronic systems, it has become necessary to integrate electromagnetic structures, which until now have been constructed with discrete components. This approach not only reduces the component count, but also gives much greater control over parasitic elements. In this article, the authors describe an electromagnetically integrated resistor-capacitor-diode (RCD) snubber/voltage clamp that uses a planar construction technique. The design and construction are described and the performance is verified experimentally. Some advantages of the integrated component over its discrete counterpart are also given     

A high-density heat-sink-mounted inductor for automotive applications

Passive components, and inductors, in particular, contribute greatly to the overall volume of power electronic converters. These components are normally packaged individually with little concern for the overall system. For high-density switching power supplies it is imperative to minimize the volume to as great an extent as possible which implies that the passive component volume usage needs to be improved. This can be accomplished by applying suitable packaging and cooling techniques to these components. In this paper, two inductor structures finding application in a 2.1-kW synchronous automotive converter are described. The air-gap placement, losses, cooling methods, and thermal profiles are analyzed and verified experimentally with an inductor designed for operation at 85/spl deg/C ambient.     

Integral 3-D thermal, electrical and mechanical design of an automotive DC/DC converter

Power electronics is finding increasingly more applications in high temperature environments where power density is also a driving factor. The engine compartment of a passenger vehicle is one such example. In this paper, an integral thermal, electrical, and mechanical design of a high power density dc/dc converter operating in the thermally harsh automotive environment is discussed. The interactions and interdependencies between the three design disciplines are considered. It is illustrated how these interactions can be manipulated and used to an advantage in meeting the harsh temperature and high power density requirements of the automotive converter. Packaging and circuit techniques are identified that can be used to this end. Two case studies of a 2-kW 14-V/42-V dc/dc converter for application in the automotive environment are considered. The first prototype achieved a power density of 170 W/in/sup 3/ while the second prototype, operating with a higher environmental temperature achieved a power density of 120 W/in/sup 3/. The experimental structures and practical results are presented. Technology issues concerning the three-dimensional construction of the prototypes that need research attention are also identified.     

High density packaging of the passive components in an automotive DC/DC converter

In this paper, a very high power density DC/DC converter module for automotive applications is investigated. The 14-V/42-V converter is specified to operate at a power level of 2.1 kW with a water cooled heat sink at 85/spl deg/C. The design and implementation of very high density passive components are discussed. Using the results of the passive component design, a prototype converter is built, achieving a final power density of 170W/in/sup 3/. The thermal performance of the passive components and the converter module under different electrical and thermal excitations is investigated and recorded. Results are presented over the full excitation range.