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Denso is expanding its hybrid component range, supplying a high-output power control unit (PCU) and a battery cooling system for the Lexus LS600h and LS600hL luxury sedans.

Hybrids need to become lighter and more space efficient to compensate for their extra complexity. High-power electronics generate a lot of heat, requiring forced cooling, but this makes systems bigger and heavier.

Denso has increased the thermal efficiency of its two modules, improving power density of the PCU by 60 per cent. It also reduces packaging requirements – for a given output the PCU can be 30 per cent smaller than a conventional design.

Denso Electric Systems’ senior managing director Mineo Hanai said: “We’ll continue to create vehicle technologies that are less harmful to the environment.”

The PCU comprises a voltage booster and two inverters supplying the traction motors with AC current. The semiconductors inside have a heat sink on both sides and are arranged in a stack between cooling tubes.

This improves cooling performance, enabling higher output. The design is more compact and can be scaled to suit different requirements.

Most hybrid battery systems achieve the required forced cooling by blowing ambient air over the surface. Denso uses cooled air from the vehicle air conditioning system. This halves the airflow requirement and cuts noise by almost one third.