COMPANY NEWS

Jul 08, 2026

A New Breakthrough for Electric Mobility｜Formitek's 7 kW Bidirectional DC/DC Converter Solves Both Charging and Range Challenges

News & Updates

April 13, 2026

As electric vehicles become increasingly widespread, charging difficulty and range anxiety remain two of the biggest concerns for EV owners.

What can drivers do when battery power runs low and no charging station is available? How can reduced range caused by aging traction batteries be addressed? Is it possible to provide emergency power support to another vehicle during long-distance travel?

Formitek(Zhoushan) Co., Ltd. provides the answer with its 7 kW Bidirectional DC/DC Converter, model XEV320D48D07K0DNW. With bidirectional energy conversion, the product delivers a energy solution for electric mobility.

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I. Product Positioning

An “Energy Dispatch Center” for Electric Vehicles

The bidirectional DC/DC converter is specifically designed for range extension in electric vehicles. Its value lies in breaking the limitations of traditional one-way power supply and enabling bidirectional energy flow between high-voltage and low-voltage systems.

Three Key Application Scenarios

Charging Station Energy Replenishment

When the vehicle is connected to a DC charging station, the converter can convert the high-voltage DC power from the charging station, 240-360 V, into low-voltage power, 40-55 V. This allows the traction battery and the low-voltage battery pack to be charged simultaneously, preventing low-voltage battery depletion.

Emergency Charging Without a Charging Station

When no charging station is available, the low-voltage battery pack can be stepped up through the converter to provide high-voltage power to the traction battery, which enables emergency range extension and helps ease range anxiety.

Vehicle-to-Vehicle Energy Sharing

The product supports power transfer between electric vehicles, making it especially useful for outdoor travel, long-distance driving, and special road conditions. It can also help extend the usable life of aging traction batteries, improving overall vehicle value and usability.

As an energy dispatch hub for electric vehicles, the product is designed in strict accordance with national standards, such as GB/T 24347-2009, and international standards, such as ISO 26262. With a reliability target of 8 years / 120,000 km, the product meets vehicle safety and environmental requirements throughout the full design and production process and is suitable for various electric vehicle models.

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II. Key Functions

Nine Key Capabilities for Efficiency, Safety, and Intelligence

The functional design of Formitek's 7 kW bidirectional DC/DC converter features high-efficiency conversion, multi-layer protection, and intelligent connectivity. Its capabilities can be summarized in nine key areas.

1. High-Efficiency Bidirectional Energy Conversion

Forward Conversion

The high-voltage side, 240-360 V, serves as the input and is converted into low-voltage output, 40-55 V. With a rated power of 7 kW and conversion efficiency of ≥95%, it meets the fast charging needs of low-voltage battery packs.

Reverse Conversion

The low-voltage side, 40-55 V, serves as the input and is boosted to high-voltage output, following the traction battery voltage. It supports both constant-current, CC, and constant-voltage, CV, modes to accommodate different power replenishment scenarios.

Voltage Following Function

When the voltage difference between the main circuit and the converter is detected to be less than 5 V, the converter automatically connects to the main battery. It dynamically adjusts output voltage to prevent voltage fluctuations from damaging the battery.

2. Intelligent CAN Communication and Calibration

The converter supports CAN bus communication and can seamlessly interface with onboard systems such as the VCU and BMS. It provides real-time feedback on operating status, including voltage, current, temperature, and other key parameters.

It also supports CAN-based online firmware updates and parameter calibration, allowing flexible adjustment of charging modes, current thresholds, and voltage thresholds to meet the requirements of different vehicle manufacturers.

3. Multiple Safety Protection Mechanisms

The product features a comprehensive protection system from both hardware and software.

It also includes battery reverse-connection protection, insulation resistance protection, with input-to-housing resistance of ≥20 × 10⁶ Ω, and grounding protection, with grounding resistance of ≤0.1 Ω. These protections help reduce risks such as electric shock and fire at the source.

4. Low Power Consumption and Fast Response

• Sleep current: ≤10 mA, reducing energy loss when the vehicle is parked or idle.

• Output response time: ≤200 ms.

• Dynamic recovery time: ≤5 ms.

• Under load changes, 30%-80%-30%, voltage fluctuation remains within ±5%, ensuring stable power supply.

5. Natural Cooling Design

The product adopts a natural air-cooling solution, requiring no additional fan. This reduces noise and lowers the risk of mechanical failure.

It is designed for operation across a wide temperature range of -40°C to 85°C. Under high-temperature conditions, 70°C to 85°C, the product automatically reduces power output to prevent overheating damage.

6. Flexible Wake-Up and Power-Down

The converter supports multiple wake-up modes, including power-on wake-up, CAN wake-up, and hardware-level wake-up, 8-16 V, making it compatible with different onboard control logic.

After the main power supply is shut down, the circuit automatically powers off to prevent leakage current and improve safety.

7. High-Precision Monitoring and Diagnostics

• Output voltage accuracy: ≤±2%.

• Monitoring accuracy: ±0.2 V.

• Supports OBD online diagnostics, enabling real-time circuit fault detection and fault code reporting through CAN for easier maintenance and troubleshooting.

8. High Environmental Adaptability

Vibration Resistance

Complies with ISO 16750-3. No structural damage occurs after horizontal and vertical vibration testing.

Protection Rating

The high-voltage connector is rated IP65 waterproof, allowing operation in rain, mud, and other complex road conditions.

Electromagnetic Compatibility, EMC

Meets standards including CISPR 25 Level 2 and ISO 7637-2, helping prevent interference with onboard electronic systems.

9. Parallel Expansion Capability

The product can break the power limitation of a single unit. Multiple 7 kW bidirectional DC/DC converters can be connected in parallel according to actual power demand, enabling flexible power scaling, such as 14 kW with two units or 21 kW with three units. This makes it suitable for power requirements ranging from household to commercial and industrial energy storage applications.

The system is equipped with automatic current-sharing technology. When operating in parallel, it automatically distributes load current to ensure consistent operation, avoid overload, and maintain stable and efficient system performance.

Parallel expansion is simple and cost-effective, whether upgrading an existing system or building a new one. This greatly improves system flexibility and scalability. For example, a small guesthouse may start with one unit for basic needs and later expand by adding more units in parallel. Commercial and industrial projects can also configure systems on demand to build customized energy storage solutions.

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III. Module Breakdown

Parameters and Structural Design That Demonstrate Strong Technical Capability

A high-quality DC/DC converter depends on precise electrical parameters and a well-engineered structural design. Formitek's product adopts a new topology and integrates advanced digital control algorithms, delivering outstanding performance across key indicators.

Structural and Interface Design

Compact Dimensions

Dimensions, excluding connectors: 483 mm × 121 mm × 73 mm.

The compact form factor makes it easy to install in vehicle-mounted applications.

Connector Configuration

High-voltage side:

Uses an LS032-0206F00401 board-end connector, rated IP65 waterproof, with gold-plated contacts and durability of ≥5,000 mating cycles. Rated voltage is 600 V, with large pins rated at 40 A, medium pins at 20 A, and small pins at 5 A.

Low-voltage side:

Uses ES07 series connectors, distinguished by black, red, and blue colors, with a rated current of 250 A. The plastic housing is made of PA66 + GF, with a flame-retardant rating of UL94-V0.

Appearance and Protection

The housing adopts a modular design. Resistance between the shielding layer and housing is ≤100 mΩ, ensuring grounding safety. The product has also passed reliability tests such as salt spray testing and high-low temperature cycling.

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IV. Application Scenarios

Multi-Field Applications Empowering Industrial Upgrades

Thebidirectional DC/DC converter is designed for range extension in electric vehicles. It breaks through the limitations of traditional one-way power supply and enables bidirectional energy flow between high-voltage and low-voltage systems.

With key advantages such as efficient bidirectional conversion, stable and reliable performance, and parallel expansion capability, the product is not only suitable for vehicle energy replenishment and range extension, but also widely applicable to energy storage, microgrids, mobile air conditioning, RVs, refrigerated trucks, vessels, and other fields, providing customized energy conversion solutions.

1. Residential and Commercial / Industrial Energy Storage Systems

Suitable for photovoltaic and wind power storage scenarios, enabling the storage and efficient use of clean energy.

• For residential use, a single unit can meet daily energy storage needs.

• For commercial and industrial use, multiple units can be connected in parallel to build a high-power energy storage system, enabling peak-valley electricity price arbitrage, load shifting, reduced electricity costs, and improved grid power stability.

2. Microgrid Systems

The converter can serve as a key energy management device for microgrids in industrial parks, rural areas, and similar scenarios.

• Connects distributed power sources, energy storage equipment, and loads into one energy chain, enabling bidirectional flow and precise power balancing.

• Supports parallel expansion to flexibly adapt to microgrid power requirements, improve power supply reliability and flexibility, and maximize the use of distributed energy.

3. Mobile Energy Storage Systems

Designed for mobile scenarios such as RVs, vessels, and refrigerated trucks, while also supporting mobile high-power electrical equipment such as portable air-conditioning systems. It provides a solution for power challenges across mobile applications.

• A single unit can meet routine energy storage needs for lighting, household appliances, navigation, refrigeration, and insulation.

• Multiple units can be connected in parallel to flexibly increase power output, easily supporting high-power mobile loads such as air conditioners and large refrigerators. This improves the overall power experience for mobile travel and outdoor operations.

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V. Why Choose Us?

Technical Expertise + Reliable Service Support

As a high-tech power supply brand focusing on power semiconductor technology, Formitek, formerly THINKANTECH Technology, holds nearly 70 invention patents and more than 160 intellectual property rights. The company has accumulated technical expertise in the field of bidirectional DC/DC conversion.

Strong Corporate Capabilities

Formitek(Zhoushan) Co., Ltd., formerly Nanjing THINKANTECH Co., Ltd., is a high-tech group founded by experts in power semiconductors and professionals from the power supply industry. The group has five specialized subsidiaries covering semiconductor chips, module packaging, power module products, and testing and certification. It has built a complete ecosystem from key components to high-end applications.

Strong Technical Support

The company holds nearly 70 invention patents and more than 160 intellectual property rights, with extensive technical accumulation in bidirectional DC/DC conversion.

Compliance Assurance

The product has passed both national and international standard certifications.

Customization Capability

Communication protocols, voltage and current parameters, and other product configurations can be adjusted according to the needs of vehicle manufacturers, providing dedicated solutions for specific applications.

Full Lifecycle Service

Formitek provides technical documentation support, including specifications and DVP test plans, along with fast after-sales response.

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As electric vehicles move towards higher efficiency, intelligence, and scenario-based functionality, Formitek's 7 kW bidirectional DC/DC converter not only addresses charging and range challenges, but also expands the energy application possibilities of electric vehicles.

Looking ahead, as electric vehicle technologies continue to evolve, compact yet powerful key components like this will become a key force in improving the electric mobility experience.

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Formitek(Zhoushan) Co., Ltd., formerly Nanjing THINKANTECH Co., Ltd., is a high-tech power supply brand focusing on power semiconductor technology. Guided by the strategy of “vertical technology integration + coordinated industrial development,” the company is driven by independent R&D to support domestic technological breakthroughs.

With nearly 70 patents and more than 160 intellectual property rights, dual quality management system certifications, and multiple major honors, Formitek is deeply engaged in intelligent marine electrical systems. Leveraging its industry-chain advantages, the company continues to support innovation across the industry.

Company Phone:

Marketing Center: 0755-36991759

Email:

info@formitek.com