Modular DC-DC Converter For EV

The power module converts 800V to 48V, helps EV makers reduce size and weight, and support flexible power systems for future vehicle designs.

Vicor has introduced automotive-grade power modules for 48V EV systems.The BCM6135 use Vicor-designed ICs certified to AEC-Q100 standards and have completed the PPAP process with automotive customers.

The BCM6135 is a 2.5kW bus converter with 98% efficiency that steps down 800V from the traction battery to 48V, creating a safety extra-low voltage (SELV) power supply for the vehicle. It provides built-in isolation between high and low voltage, reducing the space needed for DC-DC conversion. With a power density of 158kW/L, it helps EV designers shrink the size of the main DC-DC converter and lower vehicle weight. Its fast bidirectional current response of 8 mega amps per second enables it to act as a virtual 48V battery, replacing a 25lb physical battery and offering further cost and weight savings.

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The new Vicor module supports over 300 configuration options, giving designers flexibility and scalability for a wide range of vehicle subsystems. As the industry moves from 12V to 48V Zonal Architectures, these modules offer high efficiency in both directions of 48V conversion. All three modules can be combined to increase power output, with built-in automatic power sharing to ensure optimal performance. They are designed to handle complex power challenges across 800V, 400V, 48V, and 12V systems.

“Vicor has set a new standard for power density in the automotive industry with these scalable and flexible miniature power modules,” said Patrick Wadden, VP of the Vicor Automotive business unit. “Our high-performance converters enable new possibilities for automotive manufacturers to reduce the size and weight of power systems throughout the vehicle.”

“Our power modules make it easy to convert from the primary battery (800V or 400V) to 48V and down to load,” said Wadden. “They are very versatile, and our customers are using the modules in innovative ways that are helping them remove size and weight from their power systems.”

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