Thermal Topology Optimization for High Power Density Power Electronic Systems in Passively Cooled Housings

Weimer, Julian; Koch, Dominik; Nitzsche, Maximilian; Haarer, Jorg; Kallfass, Ingmar

doi:10.1109/dmc51747.2021.9529942

Cited by 2 publications

(1 citation statement)

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“…To significantly reduce the transformer hotspot, the additional losses are accepted and the PGS is included in the final potted prototype. As an alternative approach to further reduce the hotspot, newly developed methods of topology optimization with targeted heat flow control also show promising results [35].…”

Section: F Graphite Heat Spreadingmentioning

confidence: 99%

Miniaturization and Thermal Design of a 170 W AC/DC Battery Charger Utilizing GaN Power Devices

Weimer

Koch

Nitzsche

et al. 2022

IEEE Open J. Power Electron.

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This paper presents the design and analysis of a high-density two-stage battery charger for mid-power applications like small electric vehicles and high-performance laptops utilizing gallium nitride (GaN) power devices. In addition to adherence of maximum junction temperatures, a thermal analysis is carried out for in-housing operation, which is particularly critical for fanless wall chargers. Design measures include calorimetric semiconductor selection, half-bridge miniaturization, thermally conductive epoxy resin and reference-based convection modeling for thermally optimized component placement using 3D-stacking. Furthermore, the remaining optimization potential of the charger is estimated by virtual prototyping. A 170 W hardware prototype is developed and tested, achieving a two-stage power section efficiency of 95.4% with a maximum switching frequency of 550 kHz. This results in a power density in open-housing operation of 1.6 kW/dm 3 . Using epoxy resin, copper and graphite heat spreaders, an in-housing operation power density of 1.1 kW/dm 3 is achieved with minor reduction of output power due to surface temperature constraints.INDEX TERMS AC-DC power conversion, battery chargers, epoxy resins, gallium nitride, graphite.

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Section: F Graphite Heat Spreadingmentioning

confidence: 99%