Design and evaluation of an automotive integrated system module

Power electronic systems that are implemented in the automotive environment are expected to operate under harsh electrical and thermal conditions while achieving high power densities. One example of such a power electronic system is the bi-directional 14/42 V DC/DC converter that is utilized in the dual voltage networks of ultra modern vehicles. This paper presents the design and implementation of such an automotive converter as an integrated system module (ISM). The presented prototype achieves a high power density (120 W/in³) within the automotive environment while using the engine liquid coolant having a maximum temperature of up to 125 °C for cooling. The complete power conversion system is implemented in the ISM requiring dedicated thermal management structures for all the components, both active and passive. An overview of the design and evaluation of the automotive ISM, as well as the implementation of the novel thermal management concept required for the passive components is presented and supported with practical results.