Power Modules Offer A Route To Smaller HEV Inverters

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Helping to overcome the challenges of space constraints while electrifying existing car platforms, Infineon presents its extremely small power modules for hybrid and electric vehicles such as main inverters and generators with a typical power range of 40 to 50 kW.

The modules, called HybridPACK Double Sided Cooling (DSC), feature extremely small dimensions of only 42 mm x 42.4 mm x 4.77 mm. To support even higher power, they can be used in parallel configurations.

Inverter size in HEVs, which has to be as small as possible, is mainly defined by the power modules employed. Thus, these modules have to become smaller while providing sufficient power for the electric drivetrain. The size of a power module, in turn, depends on the power consumption of the power chips used inside, and the ability to cool these chips to stay below a maximum junction temperature.

“With only 15 nH, the stray inductance is very low while blocking voltage was increased to 700 V. Both factors support the development of inverter systems with reduced switching losses of about 25 percent and very high efficiency”, claims Infineon.

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Using integrated isolation, the modules can be directly attached to a cooler without external isolation thus simplifying system integration. Each integrated IGBT chip is equipped with an on-chip current sensor for overcurrent protection. In addition, an on-chip temperature sensor provides derating and fast shut-off in case of over-temperature.

The HybridPACK DSC modules claim to reduce the thermal resistance R thJC to 0.1 Kelvin/Watt (K/W). This is lower than the 0.12 K/W value of existing power module HybridPACK 1. This is acheived by combining double sided chip cooling with electrical isolation of the heat sinks.

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Further, the latest modules offer only 15 nH stray inductance which is about 40 percent lower compared to reference modules. The result is a reduction of switching losses by 25 percent.

Samples of the first member of the HybridPACK DSC family, the FF400R07A01E3_S6 with I Cnom of 400 A and VCES of 700 V in half-bridge configuration, will be available in September 2016. Another product with I Cnom of 200 A and V CES of 700 V in a full-bridge configuration will be offered as engineering samples in October 2016. Other variants offering different power ranges are under development.

For further details, view the full Press release.

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