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DC-DC conversion function integrated inside 800V battery pack to simplify cooling circuits and high-voltage harnesses
Infac has unveiled a design block that directly mounts Vicor's high-density DC-DC converter inside electric vehicle battery packs. The approach integrates the DC-DC conversion function that was previously installed independently outside the battery pack into the pack interior, reducing high-voltage cables and connectors while eliminating redundant cooling systems.
Infac disclosed the 800V battery pack design block with these specifications on the 14th.
Using Vicor's 800V-to-48V isolated regulation DC-DC converter, the structure lowers voltage directly from the battery pack and distributes Safety Extra Low Voltage (SELV) throughout the vehicle.
It differentiates itself from the conventional "silver-box" design by utilizing the battery pack as a centralized power hub rather than dispersing DC-DC conversion stages to independent subsystems scattered throughout the vehicle.
Mounting DC-DC conversion functionality inside the battery pack requires an extremely compact form factor.
Infac's system dimensions are 215 × 45 × 82mm (width/depth/height), with a volume of 793cm³ and weight of approximately 1.5kg, designed to avoid encroaching on battery cell space.
The company explained that the combination of Vicor's BCM6135 DC-DC converter and PRM3735 regulator met these space constraints.
By utilizing the existing liquid cooling system in the battery pack, the external separate cooling device was eliminated.
Infac presented the following advantages achieved through this design: △elimination of redundant coolant circuits △reduced high-voltage harness length and thickness △BOM cost and weight reduction from decreased numbers of brackets, enclosures, and cooling components △reduced leakage and electrical fault risks through minimized connection points and cooling paths △improved manufacturing process consistency through reduced external interfaces.
Infac stated that this design responds to the ongoing transition to 48V zone power architecture across the automotive industry.
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