14 POWER MODULES https://www.vicorpower.com/ Issue 4 2025 Power Electronics Europe www.power-mag.com struggle. Discrete systems have trouble delivering high-power-density conversion that meets these safety requirements. For discrete solutions to adhere to proper spacing standards, they need to have a larger footprint. This increase of vehicle package space is what OEMs are keen to avoid. Vicor innovative high-density power modules are compact and lightweight, offering a lot more flexibility in solving the issue of space especially for 400/800V battery application. By reducing DC-DC converter weight by as much as 50% and package volume by 60%, Vicor power modules free up space, reduce system mass and improve design efficiency. With an 80% smaller packaging size than typical bus converters, the Vicor BCM6135 has many benefits for automotive applications. It offers leading power density of 20.8kW/L and design flexibility to meet challenging creepage and clearance standards. With a peak efficiency of 98%, input range varying from 800 to 48V, and an output range of 2.4 – 55V, the BCM6135 converts high voltage to SELV (48V) very effectively. Vicor high-performance BCM® bus converters, PRM™ regulators and DCM™ DC-DC converters help OEMs easily solve creepage and clearance challenges. These modules are capable of being used in parallel to scale power when needed. With high power density and compact size, these modules can be placed in tight areas. Conversely, discrete power components that are much bulkier and less efficient cannot provide the same versatility. Overmolded power modules enable safer, smaller designs in EVs The automotive industry is in a new era of innovation that requires a fresh approach for designing for higher voltage applications such as a 400 or 800V battery pack. If not addressed properly, arcing will hamper power designs and become a safety issue. The industry challenge is to do more (adding high voltages) but within the same space. Legacy discrete solutions are not able to achieve safe distancing for higher voltages and it’s important to innovate using Vicor’s patented overmolded power modules. With power modules, the challenges stemming from creepage and clearance are eliminated. From their proprietary overmolding processes to their miniaturized dimensions, Vicor high-density power modules are simplifying design challenges for creepage and clearance requirements. They are also able to deliver reliability and high efficiency while simultaneously downsizing designs and broadly eliminating arcing concerns for the OEM. Figure 4: The ability of Vicor’s solutions to efficiently address coverage and clearance requirements has important residual benefits. With Vicor products, the industry can transition from a hefty silver box, filled with hundreds of components, to a smaller, lighter more efficient enclosure. The smaller power modules enable the DC-DC converters, on board charger and inverter to be housed in a small box. Figure 5: BCM®, PRMTM and DCMTM power modules effectively address safety requirements while delivering high efficiency and minimising space consumption
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