The electrical, thermal and spatial integration of a converter in a power electronic module

The electrical, thermal and spatial integration of a converter in a power electronic module

Gerber, M.B.

Ferreira, J.A. (promotor)

Electrical Engineering, Mathematics and Computer Science

2005-12-08

This thesis is concerned with the design and implementation of a power electronic system (14/42V DC/DC converter) that is implemented in the automotive environment, specifically the engine compartment. The power electronic system must have a high power density while operating in a high temperature environment. Power electronic modules are considered the technology base in which to implement the automotive converter. Of the power electronic modules considered, the Integrated System Module (ISM) is proposed for the automotive application. The ISM is a power electronic module that not only includes the power semi-conductor devices, but also contains all the additional passive components required for energy storage and if required, EMI filters. To design the automotive ISM with a high power density and high operating temperature capability, the electrical design of the topology, the thermal design of the module and the spatial and volumetric design of the physical module and components must all be optimised simultaneously. This can only be achieved by considering the interdependencies and trade-offs between the various designs and manipulating the interdependencies to simultaneously optimise all of the relevant parameters such as the power density and operating temperature. The interdependencies and the manipulation of these interdependences form the core of this thesis. Several techniques for manipulating the design interdependencies and trade-offs between the various designs are considered. For the topology considered, the most important manipulation techniques include interleaving of multiple phases and the integrated heatsink structure. The interdependent electrical, thermal and spatial design presented in the thesis is used to design and implement the experimental automotive ISM. The experimental ISM implements a bi-directional 4-phase synchronous rectifier topology including all the required passive components in the module. The ISM has a measured power density of 6.11kW/dm^3 (110.5W/in^3) and an efficiency of 89% with a coolant temperature of 110ºC. At 125ºC, the efficiency drops to 88.5%. The maximum temperature-rise in the ISM at full electrical power is on the switching semi-conductors and is only 30ºC.

power electronics
power density
high temperature
packaging
power module
system integration
ism

http://resolver.tudelft.nl/uuid:f28f32fb-f420-44c1-9683-bc2a5e0ec993

09-646-4233-8

Institutional Repository

doctoral thesis

(c) 2005 M.B. Gerber