A converter is not chosen by output voltage alone. Before shortlisting a module, define the complete electrical, thermal, mechanical and compliance boundary; otherwise a part that works on the bench can still fail in production.
1. Define the electrical window
List minimum, nominal and maximum input voltage, true load current, startup surge, allowable ripple, transient recovery target and whether the output must remain isolated from the input. For battery systems, include charge and discharge voltages, not only the nominal pack label.
2. Convert electrical loss into thermal load
At 92% efficiency (for context, TI’s synchronous-boost TPS61020 reaches 96% per its datasheet), every 100W delivered creates about 8.7W of internal loss. That heat has to move through the case, mounting surface, enclosure and ambient air. Check the datasheet derating curve against your real ambient and orientation, not only the headline current rating.
3. Select topology
- Buck: input is always above the required output.
- Boost: input is below the required output.
- Buck-boost: the input crosses the output during charge/discharge or load transients.
- Isolated: ground separation, safety isolation or common-mode noise control is required.
4. Define mechanical and production requirements
Plastic housings suit compact indoor electronics; aluminum-profile cases improve heat transfer; die-cast housings provide environmental and mechanical protection for vehicle, marine and outdoor systems. Confirm footprint, hole positions, terminal access, potting, vibration and ingress-protection needs before OEM customization.
5. Plan samples and qualification
EVEVSPOWER samples are normally available in 5–10 working days, with production typically 15–30 days after confirmation. Use those units for bench validation, thermal imaging, EMC spot checks and lifetime testing before releasing the design. For custom projects, provide input/output specification, target volume, mechanical limits and compliance requirements through the project inquiry form.