Full Bridge LLC Transformers and Resonant Choke merged in one, provides up to 40-50% reduction in volume

PublishTime： 2021-10-28 Article Source：PREMO

PREMO enlarges its 3DP-Series (3DPowerTM) of High-Power Integrated Magnetic Components for Power Converters in Automotive (PHEV, HEV, BEV, or FCEV). New 3DP-11KWHVHV.

This disruptive patented solution has been designed to increase power density (decreasing power magnetic required volume), combine 2 or 3 components in 1 (saving magnetic cores), and reduce weight by 50%. A true cost-effective solution is highly demanded by the automotive sector.

Fig.1

The 3DPower, a tech disruption that merged in one a Full Bridge LLC Transformers and Resonant Choke.

PREMO, the leading manufacturer of inductive components, releases the new 11kW 3DPowerTM solution, a Full Bridge LLC Transformer 150 µH + Resonant Choke 25 µH merged in 1 single unit. This innovation provides up to 40-50% reduction in volume compared with current discrete industrial solutions for the same power management.

Most of the Power Converters (resonant topologies) in the market have a Transformer, Resonant Choke, and Output choke. Every component has its own design, core, winding, and thermal dissipation solution. 3DPowerTM is the first product to integrate two magnetics components, LLC Transformer and Resonant Choke, that share the same core and feature two orthogonal magnetic fields at all points within the core. A unique and single solution that gives a super advantage starting at the beginning of the value chain.

● Power converter design with one inductive component in mind.

●One mechanical drawing interface to fit and connect.

● This Full Bridge LLC Transformer and Resonant Choke merged in one, improving the MTBF.

● Important volume and weight reduction (-40 to -50%).

●Energy efficiency & cost-effectiveness.

● Carbon footprint reduction worldwide (energy reduction to produce magnetic cores). X3 Reduction of Ferrites.

Once the electromagnetic performance is reached, internal and external thermal links are the most important question to solve in the design of these 3D-PowerTM components: “Heat Dissipation”. Designing power densities and power sizes over 7kW turns in a heat increase. 3Dpower use CoolMagTM, a silicone-based compound compatible with the magnetics 100% focused on power magnetic electronics to dissipate the heat from the top of the magnetic to the liquid cooling plate of the bottom is required. It provides a thermal conductivity bigger than 1.7 watts/mK. The air is removed by this compound to improve heat dissipation.

Current 3DPower Full Bridge LLC Transformer and Resonant Choke at Premo

The 3DP-11KWHVHV is available with an Aluminum heatsink that acts as a direct thermal interface to the cold plate. 3DPowerTM cost-saving solution is also available with 7kW and the company is developing the 22kW solution. Designs can be fully customized according to customer requirements.

The 3DPower TM 3DP-11KWHVHV Series meets the AEC-Q200 (specific automotive quality standard) and other more restrictive customer automotive supplier standards. This greener solution has been fully tested in Premo Laboratory under real operational conditions.

Fig. 2

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