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°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/in³. 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.