Power Density Improvement in Integrated Electromagnetic Passive Modules With Embedded Heat Extractors

In this paper, heat extractors are embedded into the magnetic materials of the integrated power electronics passive modules. The optimum volume of heat-extracting material may slightly reduce the amount of electromagnetic energy that is processed, but more efficient heat removal yields higher allowable levels of both electromagnetic stress and losses per unit volume in the remaining material. Without influencing the electromagnetic performance, heat extractors provide the potential to improve the power density of passive modules. This paper introduces the mechanism of heat extractors into passive power electronics modules. Theoretical thermal models and simulation are used to investigate factors influencing the module performance and the improvement on power density. Prototypes are built for experimental investigation. The experimental results show great improvement of power density by the application of heat extraction technology. High power density, more than 1 kW/in³ (70 W/cm³), is achieved on the prototype.