A closer look at semiconductor packaging considerations in EVs
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The necessity for efficient power semiconductor packaging in electric vehicles (EVs) is paramount as the design of critical components like on-board chargers, DC/DC converters, and inverters relies heavily on the form factor of these semiconductors. The transition from traditional packaging to semi-custom modules marks a significant development in the EV industry, driven by the need for compact and cost-effective solutions that can also meet stringent electrical safety standards. This article delves into the reasons behind Tesla's decision to adopt a semi-custom power module approach, enhancing the efficiency and reliability of their vehicles.
The Role of Semiconductor Packaging in EV Design
One of the initial and crucial decisions in designing a new power converter revolves around the semiconductor packages. For EVs, the selection between plastic types like TO-220 and TO-247 packages versus modules plays a significant role.
Plastic Package Components
Plastic packages, such as TO-220 and TO-247, are commonly utilized due to their wire leads and heatsink tabs. These packages typically house either a single diode or switch. However, integration challenges arise due to the need for electrical isolation and sufficient thermal management, especially at high power levels.
Modules for High Power Applications
Modules, on the other hand, come with several pre-wired components and features like screw terminals, making them suitable for high-power requirements. Modules offer better integration and replacement convenience, with electric isolation and enhanced thermal management being significant advantages.
Tesla's Historical Usage of Semiconductor Packages
Interestingly, Tesla initially favored using TO-247 switches in their early inverters for their modularity. However, as the technology evolved, the Model 3's inverter design transitioned to a semi-custom approach, favoring devices with higher power ratings in a similar form factor.
Challenges with Traditional Power Modules
Traditional power semiconductor modules were primarily geared towards industrial applications, focusing on reliability and efficiency over compactness and noise reduction. Their voltage and power ratings were quite coarse, making them less ideal for the nuanced needs of EV applications.
Advantages of Semi-Custom Power Modules
The advanced packaging solutions adopted for Tesla's Model 3, developed in collaboration with STMicroelectronics, represent a hybrid approach. These semi-custom modules combine the cost-effectiveness and low inductance of plastic packages with the insulation, thermal performance, and high current capacity of traditional modules, tailored specifically for EV applications.
Conclusion
The shift to semi-custom power modules underscores Tesla's innovative stride towards optimizing EV performance. These modules address the specific demands of EV applications by leveraging improved thermal management, electrical isolation, and enhanced current handling, all within a cost-effective and compact design.
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SEE ALSO: A closer look at the losses in power semiconductors
Sidebar: Thermal Conductivity vs Resistance
These two specs are common in power electronics. Thermal resistance is straightforward—it's like electrical resistance but for heat. Thermal conductivity, on the other hand, is a material property that measures how well a material conducts heat. High thermal conductivity materials, like aluminum nitride, offer lower thermal resistance, which is desirable for maintaining efficient thermal management in power electronics.
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This article appeared in Charged Issue 47 – January/February 2020 – Subscribe now.
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