INFAC bolsters EV range by packing more power into the battery pack

Powering innovation

INFAC bolsters EV range by packing more power into the battery pack The solution

Power delivery network challenges

Size and weight

Thermal management

Efficient power conversion

Increasing vehicle range

Increasing EV range with higher battery power, improving power efficiency and lowering vehicle weight is a top priority for every EV OEM. The power system design challenge comes down to, how to pack more power into a smaller form factor, while enhancing efficiency. This challenge is pushing power system engineers to reimagine battery and power distribution architectures and power conversion engines, with additional focus on heavy, costly and inefficient power cables and connectors.

Vicor advantages

Power dense

Thermally adept

Highly efficient

Creating an efficient 48V zonal architecture

An EV battery pack incorporates a robust liquid cooling system designed to manage thermal loads, so INFAC re-imagined how to maximize the use of this cooling system. By integrating the high voltage DC-DC converter inside the battery, and leveraging the existing infrastructure INFAC eliminated the separate cooling system which traditionally resides outside the battery pack for the DC-DC converter. This departs from conventional “silver-box” design approaches by positioning the battery pack as a central, intelligent power hub rather than a passive energy source.

High-density power modules enable innovation

Transitioning to a 48V zonal architecture with DC-DC conversion integrated within the battery pack has been inhibited by the size and bulk of traditional DC-DC converters. Vicor high-density power modules provide the compact form factor and efficiency required to make battery-integrated 48V distribution practical at scale. Vicor high-density BCM6135 DC-DC converters and PRM3735 regulators provide HV-to-48V conversion and regulation enabling a high-power, fully isolated and regulated bus for the zonal architecture. INFAC’s novel solution using Vicor technology positions the battery pack as a central power management and distribution hub for next-generation electric vehicles.