Double-Side Manifold Micro-Channel Cold Plate for High Power Density Composite DC-DC Converter

To enhance the efficiency of power electronics, a composite DC-DC converter architecture has been proposed based on the literature, which addresses the loss mechanisms associated with indirect power conversion explicitly over a wide range of operating conditions, especially at moderate-to-low workload. While the composite DC-DC converter possesses lower power losses and high reliability, it also has numerous components that generate heat and require thermal management, including power modules and planar magnetic components. The magnetic components include planar inductors and a planar transformer. To achieve a compact, power-dense overall composite boost converter structure, a double-side manifold micro-channel cold plate was developed. The physical architecture of the composite converter was optimized to strategically position the power modules and planar inductors on opposite sides of the thin form-factor cold plate. A volumetric power density of 21.3 kW/L, with a system volume of 5.9 L and maximum power of 126 kW was achieved. Packaging, design, and fabrication details of the system and unique multi-component cold plate are provided. Cold plate heat transfer coefficients, in the range of 10–22 kW/m2-K, with a pressure drop of ~9 kPa at a coolant flow rate of 10 L/min, were achieved to satisfy a range of component cooling requirements.