Vicor has released a new series of automotive-grade power modules designed to improve efficiency and reduce weight in 48V electric vehicle (EV) systems, supporting the industry’s shift to higher voltage architectures.
The three new modules developed by Vicor—BCM6135, DCM3735, and PRM3735—are tailored for 48V EV systems and have completed the rigorous PPAP process. These power modules, set for production in 2025, offer superior power density and efficiency, enabling automotive manufacturers to optimize their vehicle power systems. The target audience for these products includes automotive OEMs, tier-one suppliers, and electric vehicle designers who are seeking compact, highly efficient solutions for power conversion in next-generation EVs.
The BCM6135 module is a highly efficient 2.5kW bus converter that transforms 800V from the traction battery to 48V. This module’s 98% efficiency and power density of 158kW/L help EV designers significantly reduce the size and weight of their power systems. By acting as a virtual 48V battery, the BCM6135 can eliminate the need for a separate 48V battery, reducing vehicle weight by up to 25kg and cutting costs by approximately $100 as claimed by company.
The DCM3735 is a 2.0kW DC-DC converter that steps down 48V to a regulated 12V output, making it versatile for various automotive applications. It has a power density of 300kW/L and can be used in zonal architectures where 48V subsystems power 12V loads. Its flexibility allows it to be configured for different voltage ranges, providing value to manufacturers aiming for zonal electrical distribution.
The PRM3735, a 2.5kW regulator with an impressive 99.2% efficiency, is designed for 48V power regulation. Its compact footprint and power density of 260kW/L make it ideal for reducing the overall size of DC-DC power supplies in EVs, freeing up valuable space.
“The flexibility and scalability of these modules set a new standard for power systems in electric vehicles,” said Patrick Wadden, VP, Automotive business unit, Vicor. “Our customers are using these modules to improve efficiency while also removing size and weight from their power systems,” Wadden further added.
These modules also play a vital role in supporting the industry’s transition to 48V zonal architectures. With over 300 possible configurations, they simplify the conversion between 800V, 400V, 48V, and 12V systems. Their high-speed response rate and bidirectional capabilities make them particularly suitable for advanced applications such as active suspension systems and precharging, ensuring smooth and efficient power management.
The new power modules are expected to redefine power delivery networks in EVs, offering substantial savings in weight, space, and cost
