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Silicon carbide (SiC) metal–oxide–semiconductor field effect transistors (MOSFETs) have seen rapid growth in recent years, thanks to its low conduction loss, fast switching speed, and good thermal conductivity. For high power applications, it is necessary to parallel two or more devices in order to achieve the desired current rating, conduction loss, and thermal performance. Traditional single-driver multi-chip module (SDM) requires strong drivers and suffers a lot from parasitic parameter mismatch induced transient current unbalance and intrinsic oscillation. To reduce the thermal imbalance and operation risks, the switching speeds of parallel MOSFETs or MOSFET modules in general are usually slowed with larger gate resistance, at the expense of higher switching loss. Therefore, this solution is not optimal since it indicates a poor utilization of the SiC MOSFET’s intrinsic high-speed capability. The research developed analytical models for the transient current sharing and inherent oscillation for two paralleled SiC MOSFETs’ switching process. The transient current sharing model is developed based on linearized circuit state equations, while the intrinsic oscillation model is based on small-signal equivalent circuits. By using these models, the influences of parasitic parameters are investigated. The optimized gate resistor selection to compensate circuit mismatches is discussed. Based on the studies and models, a 650 V, 300 A double-side cooling GaN HEMT based SDM is designed and fabricated. A better configuration of the multi-driver multi-chip module (MDM) is proposed and the performances are compared. The analytical models provide a fast way to evaluate and optimize the design or approach of any paralleled MOSFET cases. The proposed MDM solution could be a more efficient, more reliable power module design configuration. The parameter influence and comparison results were verified in the experimental tests
The accelerating commercialization of wide bandgap technology has led to increased demand for accurate circuit-level simulation models of devices such as Silicon-Carbide (SiC) MOSFET power modules. These models assist with optimizing systems to minimize overshoot and electromagnetic interference (EMI) associated with wide bandgap (WBG) switching conditions. As a result, capturing these behaviors requires more detailed and advanced modeling and characterization techniques than traditional Silicon (Si) semiconductors. These advancements include improvements to the parasitic package model, transistor characterization, and computational efficiency of the synthesized model. In this dissertation, a commercially available half-bridge SiC power module is characterized and modeled in SPICE. Simulation and empirical characterization techniques are used to quantify the packaging parasitics of the module. These parasitics include self-inductances, mutual coupling terms, and baseplate capacitances (BPC) that are sensitive to the high di/dt and dv/dt events that occur during switching transitions. The simulation predictions and empirical measurements are used to cross-validate each other and determine the preferred method for quantifying each parasitic parameter. The SiC transistors are characterized using a combination of commercial equipment and custom measurement techniques. The characterization process is described in detail and sensitivities are uncovered in that are crucial to the modeling effort. The characterization includes an advanced conduction analysis (ACA) system that combined with a self-heating removal algorithm is capable of quantifying the short-channel behavior of the device at high voltage. Finally, the package model and SiC MOSFET characteristics are used to synthesize a compact behavioral model. The model is evaluated in terms of its accuracy through comparison of quantitative error metrics across a wide range of double pulse test (DPT) operating conditions. The model is also evaluated in a multi-level inverter simulation to determine its computational efficiency and convergence behavior. It is shown that the model is highly accurate across the selected range of operating conditions and is capable of converging quickly in complex circuit topologies.
Wide Bandgap semiconductor devices offer higher efficiency, smaller size, less weight, and longer lifetime, with applications in power grid electronics and electromobility. This book describes the state of advanced packaging solutions for novel wide-band-gap semiconductors, specifically silicon carbide (SiC) MOSFETs and diodes.
This book will be a collection of the conference manuscripts presented at the 2022 2nd International Joint Conference on Energy, Electrical and Power Engineering covering new and renewable energy, electrical and power engineering. It is expected to report the latest technological developments in the fields developed by academic researchers and industrial practitioners. The application and dissemination of these technologies will benefit the research community, as new research directions are becoming increasingly interdisciplinary, requiring researchers from different research areas to come together and share ideas. It will also benefit the electrical engineering and energy industry, as we are now experiencing a new wave of industrial revolution, i.e. the electrification, intelligentisation and digitalisation of our transport, manufacturing processes and way of thinking.
Increasing demand for efficiency and power density pushes Si-based devices to some of their inherent material limits, including those related to temperature operation, switching frequency, and blocking voltage. Recently, SiC-based power devices are promising candidates for high-power and high-frequency switching applications. Today, SiC MOSFETs are commercially available from several manufacturers. Although technology affiliated with SiC MOSFETs is improving rapidly, many challenges remain, and some of them are investigated in this work. The research work in this dissertation is divided into the three following parts. Firstly, the static and switching characteristics of the state-of-the-art 1.2 kV planar and double-trench SiC MOSFETs from two different manufacturers are evaluated. The effects of different biasing voltages, DC link voltages, and temperatures are analysed. The characterisation results show that the devices exhibit superior switching performances under different operating conditions. Moreover, several aspects of using the SiC MOSFET’s body diode in a DC/DC converter are investigated, comparing the body-diodes of planar and double-trench devices. Reverse recovery is evaluated in switching tests considering the case temperature, switching rate, forward current, and applied voltage. Based on the measurement results, the junction temperature is estimated to guarantee safe operation. A simple electro-thermal model is proposed in order to estimate the maximum allowed switching frequency based on the thermal design of the SiC devices. Using these results, hard- and soft-switching converters are designed, and devices are characterised as being in continuous operation at a very high switching frequency of 1 MHz. Thereafter, the SiC MOSFETs are operated in a continuous mode in a 10 kW / 100-250 kHz buck converter, comparing synchronous rectification, the use of the body diode, and the use of an external Schottky diode. Further, the parallel operation of the planar devices is considered. Thus, the paralleling of SiC MOSFETs is investigated before comparing the devices in continuous converter operation. In this regard, the impact of the most common mismatch parameters on the static and dynamic current sharing of the transistors is evaluated, showing that paralleling of SiC MOSFETs is feasible. Subsequently, an analytical model of SiC MOSFETs for switching loss optimisation is proposed. The analytical model exhibits relatively close agreement with measurement results under different test conditions. The proposed model tracks the oscillation effectively during both turn-on and –off transitions. This has been achieved by considering the influence of the most crucial parasitic elements in both power and gate loops. In the second part, a comprehensive short-circuit ruggedness evaluation focusing on different failure modes of the planar and double-trench SiC devices is presented. The effects of different biasing voltages, DC link voltages, and gate resistances are evaluated. Additionally, the temperature-dependence of the short-circuit capability is evaluated, and the associated failure modes are analysed. Subsequently, the design and test of two different methods for overcurrent protection are proposed. The desaturation technique is applied to the SiC MOSFETs and compared to a second method that depends on the stray inductance of the devices. Finally, the benefits of using SiC devices in continuous high-frequency, high-power DC/DC converters is experimentally evaluated. In this regard, a design optimisation of a high-frequency transformer is introduced, and the impact of different core materials, conductor designs, and winding arrangements are evaluated. A ZVZCS Phase-Shift Full-Bridge unidirectional DC/DC converter is proposed, using only the parasitic leakage inductance of the transformer. Experimental results for a 10 kW, (100-250) kHz prototype indicate an efficiency of up to 98.1% for the whole converter. Furthermore, an optimized control method is proposed to minimise the circulation current in the isolated bidirectional dual active bridge DC/DC converter, based on a modified dual-phase-shift control method. This control method is also experimentally compared with traditional single-phase shift control, yielding a significant improvement in efficiency. The experimental results confirm the theoretical analysis and show that the proposed control can enhance the overall converter efficiency and expand the ZVZCS range. Die steigende Nachfrage nach Effizienz und Leistungsdichte bringt Si-basierte eistungsbauteile an einige inhärente Materialgrenzen, die unter anderem mit der Temperaturbelastung, der Schaltfrequenz und der Blockierspannung in Zusammenhang stehen. In jüngster Zeit sind SiC-basierte Leistungsbauelemente vielversprechende Kandidaten für Hochleistungs- und Hochfrequenzanwendungen. Aktuell sind SiC-MOSFETs von mehreren Herstellern im Handel erhältlich. Obwohl sich die Technologie der SiC-MOSFETs rasch verbessert, werden viele Herausforderungen bestehen bleiben. Einige dieser Herausforderungen werden in dieser Arbeit untersucht. Die Untersuchungen in dieser Dissertation gliedern sich in die drei folgenden Teile: Im ersten Teil erfolgt, die statische und die transiente Charakterisierung der aktuellen 1,2 kV Planarund Doubletrench SiC-MOSFETs verschiedener Hersteller. Die Auswirkungen unterschiedlicher Gatespannungen, Zwischenkreisspannungen und Temperaturen werden analysiert. Die Ergebnisse der Charakterisierung zeigen, dass die Bauteile überlegene Schaltleistungen unter verschiedenen Betriebsbedingungen aufweisen. Darüber hinaus wird der Einsatz der internen SiC-Bodydioden in einem DC/DC-Wandler untersucht, wobei die Unterschiede zwischen Planar- und Doppeltrench-Bauteilen aufgezeigt werden. Das Reverse-Recovery-Verhalten wird unter Berücksichtigung der Gehäusetemperatur, der Schaltgeschwindigkeit, des Durchlassstroms und der angelegten Spannung bewertet. Anhand der Messergebnisse wird die Sperrschichttemperatur geschätzt, damit ein sicherer Betrieb gewährleistet ist. Ein einfaches elektrothermisches Modell wird vorgestellt, um die maximal zulässige Schaltfrequenz auf der Grundlage des thermischen Designs der SiC-Bauteile abzuschätzen. Anhand dieser Ergebnisse werden hart- und weichschaltende Umrichter konzipiert und die Bauteile werden im Dauerbetrieb mit einer sehr hohen Schaltfrequenz von 1 MHz untersucht. Danach werden die SiC-MOSFETs im Dauerbetrieb in einem 10 kW / 100-250 kHz-Tiefsetzsteller betrieben. Dabei wird die Synchrongleichrichtung, die Verwendung der internen Diode und die Verwendung einer externen Schottky-Diode verglichen. Außerdem wird die Parallelisierung von SiC-MOSFETs untersucht, bevor die Parallelschaltung der verschiedenen Bauelemente ebenso im kontinuierlichen Konverterbetrieb verglichen wird. Es wird der Einfluss der häufigsten Parametervariationen auf die statische und dynamische Stromaufteilung der Transistoren analysiert, was zeigt, dass eine Parallelisierung von SiC-MOSFETs möglich ist. Anschließend wird ein analytisches Modell der SiC-MOSFETs zur Schaltverlustoptimierung vorgeschlagen. Das analytische Modell zeigt eine relativ enge Übereinstimmung mit den Messergebnissen unter verschiedenen Testbedingungen. Das vorgeschlagene Modell bildet die Schwingungen sowohl beim Ein- als auch beim Ausschalten effektiv nach. Dies wurde durch die Berücksichtigung der wichtigsten parasitären Elemente in Strom- und Gatekreisen erreicht. Im zweiten Teil wird eine umfassende Bewertung der Kurzschlussfestigkeit mit Fokus auf verschiedene Ausfallmodi der planaren und double-trench SiC-Bauelemente vorgestellt. Die Auswirkungen unterschiedlicher Gatespannungen, Zwischenkreisspannungen und Gate-Widerstände werden ausgewertet. Zusätzlich wird die temperaturabhängige Kurzschlussfähigkeit ausgewertet und die zugehörigen Fehlerfälle werden analysiert. Anschließend wird die Auslegung und Prüfung von zwei verschiedenen Verfahren zum Überstromschutz evaluiert. Die „Desaturation“-Technik wird auf SiC-MOSFETs angewendet und mit einer zweiten Methode verglichen, welche die parasitäre Induktivität der Bauelemente nutzt. Schließlich wird der Nutzen des Einsatzes von SiC-Bauteilen in kontinuierlichen Hochfrequenz-Hochleistungs-DC/DC-Wandlern experimentell untersucht. In diesem Zusammenhang wird eine Designoptimierung eines Hochfrequenztransformators vorgestellt und der Einfluss verschiedener Kernmaterialien, Leiterausführungen und Wicklungsanordnungen wird bewertet. Es wird ein unidirektionaler ZVZCS Vollbrücken-DC/DC-Wandler vorgestellt, der nur die parasitäre Streuinduktivität des Transformators verwendet. Experimentelle Ergebnisse für einen 10 kW, (100-250) kHz Prototyp zeigen einenWirkungsgrad von bis zu 98,1% für den gesamten Umrichter. Abschließend wird ein optimiertes Regelverfahren verwendet, welches auf einem modifizierten Dual-Phase-Shift-Regelverfahren basiert, um den Kreisstrom im isolierten bidirektionalen Dual-Aktiv-Brücken-DC/DC-Wandler zu minimieren. Diese Regelmethode wird experimentell mit der herkömmlichen Single-Phase-Shift-Regelung verglichen. Hierbei zeigt sich eine deutliche Effizienzsteigerung durch die neue Regelmethode. Die experimentellen Ergebnisse bestätigen die theoretische Analyse und zeigen, dass die vorgeschlagene Regelung den Gesamtwirkungsgrad des Umrichters erhöhen und den ZVZCS-Bereich erweitern kann.
With the benefits of fast switching speed, low on-resistance and high thermal conductivity, silicon carbide (SiC) devices are being implemented in converter designs with high efficiency and high power density. Consequently, SiC power modules are needed. However, some of the preestablished package designs for silicon based power modules are not suitable to manifest the advantages of SiC devices. Therefore, this thesis aims at optimizing the package design to utilize the fast switching capability of SiC devices. First, the power loop parasitic inductance induced by the package can lead to large voltage spikes with the fast switching SiC device. It can potentially exceed the device's voltage ratings and affect its safe operation. Second, to achieve high power density design with SiC devices, the package's cooling performance needs to be improved. Third, to design a package for high current applications with multiple chips in parallel, a proper scaling method is needed to ensure all the devices undertake the same voltage stress in switching transients. For P-cell/N-cell designs with split scaling, a new parasitic parameter, namely, middle-point parasitic inductance Lm̳i̳d̳d̳l̳e̳ will be introduced. Its role should be understood. Lastly, the unbalanced dynamic switching loss can lead to different state junction temperatures among paralleled devices. Thermal coupling can help to reduce the temperature imbalance, and its role should be quantitatively investigated. To meet the first two requirements, a new package design is proposed with reduced parasitic inductance and double-sided cooling. Compared to a baseline package, more than 60% reduction of parasitic inductance is achieved. The middle-point parasitic inductance's effect on device's switching transients is analyzed in the frequency domain. Then a dedicated power module is fabricated with the capability of varying Lm̳i̳d̳d̳l̳e̳. Experiment results show that as Lm̳i̳d̳d̳l̳e̳ increases, different voltage stresses are imposed on the MOSFET and anti-parallel diode. Electrothermal simulations are implemented to investigate steady state junction temperatures of paralleled devices considering unbalanced switching losses at different thermal coupling conditions. It is observed that both devices' junction temperatures will increase as the coupling coefficient is increased. However, the junction temperature imbalance will decrease. This is verified by the experiment result.
The primary goal of this book is to provide a sound understanding of wide bandgap Silicon Carbide (SiC) power semiconductor device simulation using Silvaco© ATLAS Technology Computer Aided Design (TCAD) software. Physics-based TCAD modeling of SiC power devices can be extremely challenging due to the wide bandgap of the semiconductor material. The material presented in this book aims to shorten the learning curve required to start successful SiC device simulation by providing a detailed explanation of simulation code and the impact of various modeling and simulation parameters on the simulation results. Non-isothermal simulation to predict heat dissipation and lattice temperature rise in a SiC device structure under switching condition has been explained in detail. Key pointers including runtime error messages, code debugging, implications of using certain models and parameter values, and other factors beneficial to device simulation are provided based on the authors' experience while simulating SiC device structures. This book is useful for students, researchers, and semiconductor professionals working in the area of SiC semiconductor technology. Readers will be provided with the source code of several fully functional simulation programs that illustrate the use of Silvaco© ATLAS to simulate SiC power device structure, as well as supplementary material for download.
The design of power converters relies on computer modeling to accurately predict system electrical and thermal behavior prior to implementation. In the field of wide bandgap semiconductors, the extraordinarily high switching speed of silicon-carbide devices dictates that traditionally inconsequential parasitic elements can impact system level behavior. This is especially true for systems implementing multi-chip power modules. To ensure accurate simulations, a new and precise methodology for modeling these systems is needed. This thesis formulates a measurement based and empirically-validated methodology for modeling wide bandgap power modules. First, impedance analysis is used to create a parasitic model of the power module's frequency domain behavior. Second, double pulse testing is implemented to characterize the dynamic behavior of the power module. Next, a SPICE model is developed from the frequency and time domain measurements. Finally, the model is validated through its accurate prediction of time domain waveforms and switching losses.
During the last decade many new concepts have been proposed for improving the performance of power MOSFETs. The results of this research are dispersed in the technical literature among journal articles and abstracts of conferences. Consequently, the information is not readily available to researchers and practicing engineers in the power device community. There is no cohesive treatment of the ideas to provide an assessment of the relative merits of the ideas. "Advanced Power MOSFET Concepts" provides an in-depth treatment of the physics of operation of advanced power MOSFETs. Analytical models for explaining the operation of all the advanced power MOSFETs will be developed. The results of numerical simulations will be provided to give additional insight into the device physics and validate the analytical models. The results of two-dimensional simulations will be provided to corroborate the analytical models and give greater insight into the device operation.