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Wide Band Gap Applications 1 Wide Band Gap Applications 2 Wide Band Gap Overview • Types: – Gallium Nitride (GaN) • Volume production since the 1990’s • Primary Applications: ‒ RF ‒ LED Remember Carborundum? – Silicon Carbide (SiC) • Commercial production since 2008 • Primary Applications: ‒ Power Inverters Especially attractive at 1.2+ kV ‒ Low Voltage Power Distribution • Advantages over Silicon ‒ Efficiency ‒ High Frequency ‒ High Temperature ‒ High Voltage • Withstand 10x Voltage Cree SiC MOSFET Six-Pack Power Module © 2019 KEMET Corporation Wide Bandgap (WBG) Semiconductors Semiconductor Material Bandgap Energy (eV) Germanium (Ge) 0.7 Silicon (Si) 1.1 Silicon Carbide (SiC) 3.3 Gallium Nitride (GaN) 3.4 WBG Electron Electron Energy Insulators Semiconductors Conductors Non-Conductive band Conductivity (S/cm) 10-20 10-16 10-12 10-8 10-4 100 104 108 Density of States © 2019 KEMET Corporation Wide Bandgap (WBG) Semiconductors 100M The BIG 3 for WBG 10M SiC • Higher Voltages Power Converter • Higher Frequencies 1M • Higher Temperatures 100k 10k Si Power Power (W) 1k Si GaN 100 10 100 1k 10k 100k 1M 10M 100M 1G 10G 100G Frequency (Hz) © 2019 KEMET Corporation Wide Band Gap Overview • Lower System Losses – Increased Frequency – Smaller Size • Passive Component Impact: – 10x to 100x+ smaller value: • Inductor • DC Link capacitor – Power Inverters: • 150 to 175+ degree C Snubber • Snubber integrated into IC package (Ceramic) • Ceramic DC Link ‒ Frequency response ‒ Temperature ‒ Smaller capacitance required ‒ Up to 1200V and 1700V © 2019 KEMET Corporation Power Film Technology (Metallized PP) Effect of Higher Temperature and Frequency • Higher Temperature – Shorter Life, Lower Reliability – Voltage & Current Limitation • Higher Frequency – Higher DF – Voltage & Current Limitation © 2019 KEMET Corporation Future Power Electronics Semiconductor vs. Power vs. Frequency Source: P. Friedrichs & M. Buschkuhle, Infineon AG, Energetica India, May/June 2016 © 2019 KEMET Corporation Power Electronics Benefits • Compared to Si, Wide Band Gap (WBG) IGBT and Power Modules: – Are smaller – Require less cooling – Are more energy efficient Conversion Efficiency Si Based WBG Based GaN or SiC DC to DC 85% 95% AC to DC 85% 90% DC to AC 96% 99% Source: Mouser Electronics, L. Culberson, 2016 • Snubber and DC Link capacitors requirements for AC/DC conversions in high power inverters and converters will be reviewed © 2019 KEMET Corporation Power Converter Capacitors System Overview: AC ~ AC ~ AC/DC DC/AC Power 0 Converter Inverter Power Source 2 2 Load 1 3 1 Typical Capacitor Types: 0 EMI / RFI 1 AC Harmonic Filter 3Φ 2 Snubber 3 DC Link Filter 1Φ L1 CY Power line CX equipment L2 CY © 2019 KEMET Corporation WBG Capacitor Requirements WBG Semiconductor Trend Capacitor Requirement Higher Switching Frequencies Smaller, low ESR, low ESL low 20kHz → 100kHz → 100’s MHz loss capacitors with high dV/dt & current handling capability Higher Operation Voltages Reliable performance at higher 400V → 900V →1200V→1700V voltages GaN SiC High Junction Temperatures Reliable performance at elevated 105oC → 125oC → 200oC+ temperatures ≥ 125oC with SiC robust mechanical performance • Packaging close to the hot semiconductor to: ‒ Lower ESL ‒ Minimize cooling costs © 2019 KEMET Corporation Wide Bandgap Trend Impact on Capacitors DC-LINK Capacitance vs Switching Frequency and Voltage of a 10kW Power Converter 400V 650V 1000V 10 1 ) uF Higher Voltage = Lower Capacitance 0.1 Capacitance ( Capacitance 0.01 푃 퐶 = 푙표푎푑 푉 푉 푉푚푎푥 − 푟푖푝푝푙푒 ∗ 2 ∗ 휋 ∗ 푓푟푒푞푢푒푛푐푦 푟푖푝푝푙푒 2 0.001 10 100 1000 10000 Frequency kHz * Source: Prof. R. Kennel, Technical University Munich, Germany © 2019 KEMET Corporation Capacitance Vs. Switching Frequency Example: 10% Ripple for different power & voltage Frequency 10kW 50kW 100kW Voltage 20 5.24μF 26.19μF 52.38μF 60 1.75μF 8.73μF 17.46μF 400 100 1.05μF 5.24μF 10.48μF 140 0.75μF 3.74μF 7.48μF 20 1.98μF 9.92μF 19.84μF 60 0.66μF 3.31μF 6.61μF 650 100 0.40μF 1.98μF 3.97μF 140 0.28μF 1.42μF 2.83μF 20 0.84μF 4.19μF 8.38μF 60 0.28μF 1.40μF 2.79μF Higher Voltage 1000 100 0.17μF 0.84μF 1.68μF Less Cap 140 0.12μF 0.60μF 1.20μF Higher Power More Cap © 2019 KEMET Corporation Capacitance vs. Switching Frequency Polypropylene Film to MLCC • For DC-Link Capacitors: ‒ Lower capacitance required promotes miniaturization due to: • Increasing switching frequency • Higher voltages • Lower capacitance is within the range of MLCC. ‒ But these must be: • Extremely reliable • Over-temperature capable • Over-voltage capable • High current capable • Mechanically robust • PRO-TIP: MLCC for effective switching noise suppression when placed close to WBG where cooling is limited. © 2019 KEMET Corporation Ceramic Dielectric Types High Energy Storage & MLCC Attributes Paraelectric Ferroelectric Anti-Ferroelectric EIA Class-I Class-II Class-II Types C0G, C0H, U2J X7R, X5R Similar to Y5V PbLaZrTiO Dielectric CaZrO BaTiO3 3 3 • C0G Development, Leadless Stacks for Higher Cap & U2J Dielectric with Higher K MLCC Attributes Target Paraelectric CaZrO3 Ferroelectric BaTiO3 Anti-Ferroelectric PLZT Energy Storage High High Low High Dielectric Constant K High Low High High Dielectric Loss DF Low Low High Medium Current Handling High High Low Medium Mechanical Robustness High High Medium Low Piezo (Electrostriction) Low Low High High Voltage Stability High High Low Medium Temperature Stability High High© 2019 KEMET Corporation Medium Low 3640 0.22µF 500V Ni BME C0G for 150oC Temperature Accelerated HALT • MLCC were HALT tested at 260oC at 1000, 1100, 1200 & 1300VDC (n = 40, with Au term.) • MTTF Vs. Voltage was recorded • Voltage exponent ~ 19 @ 260°C • Calc. MTTF @ 500V ~ 8500 years DC MTTF = 2934 min. y = 7.13E+59x-18.6 © 2019 KEMET Corporation Performance Comparison 3640 Ni BME C0G vs. Competitor Cu PLZT 3640 0.23cm3 Vs. Cu PLZT 0.35cm3 – 3640 0.22μF has better accelerated life, stable cap with temperature / voltage & less ripple heating – > 0.33μF with Leadless Stack Solutions © 2019 KEMET Corporation Ni BME C0G MLCC 3640 0.22µF 500V 150oC Mechanical & Surface Mounted Performance • Large Case C0G MLCC have No Lead Flex. Term. Or Lead – High MOR – Board Flex > 3mm – Pass AEC Q200 temp. cycle testing Case Size Cap. Rated 1000 Cycles 50 Cycles (nF) Voltage -55oC to +125oC -55oC to +200oC (VDC) Tested 4540 27 1500 0/231 0/50 Pieces to 10mm DID 3640 15 2000 0/154 0/100 NOT FAIL 3040 39 1000 0/154 0/100 2824 33 630 0/154 0/100 © 2019 KEMET Corporation Ni BME C0G MLCC 3640 0.22µF 500V 150oC ESR & Current Handling @ 150oC 100kHz • Lower DF & ESR reduce the power dissipated ESR < 3 mΩ P = power dissipated i = current d = dissipation factor f = frequency C = capacitance R = resistance, ESR Ripple Current Life Testing • No failures after 1000hrs @150oC – 15ARMS 100kHz – 10ARMS 100kHz with 400VDC Bias © 2019 KEMET Corporation 3640 0.22µF 500V 150oC Thermal Resistance & Ripple Current • Measured Thermal Resistance correlates closely to calculated value of 14.1oC/W • DC Voltage limits ripple current at lower frequencies ≤ 100kHz • Maximum ripple currents are based on not exceeding the 150oC temperature or voltage capability © 2019 KEMET Corporation Performance • PRO-TIP: Ideal for Resonant Capacitors C0G 3640 220nF 500V © 2019 KEMET Corporation 3640 0.22µF 500V 150oC Part Number & Properties CKC 33 C 224 K C G A C TU Case Size Specification/ Capacitance Capacitance Rated Voltage Subclass Termination Packaging Series Dielectric (L"x W") Series Code (pF) Tolerance (V) Designation Finish (Suffix / C-Spec) CKC = KC-LINK 33 = 3640 C = Standard 2 Sig. Digits + K = ±10% C = 500 V G = C0G A = N/A C = 100% Matte Sn TU= 7" Reel, Unmarked Number of Zeros © 2019 KEMET Corporation Thermal Modeling & Ranges Case Size 3640 0.22μF, 500V o • Thermal Resistance RƟ ( C/W) models Max. Cap. Range correlate well with experimental results 1812 2220 3640 KC-LINK Voltage Rating Voltage Rating Cap, uF Cap Code 650 1000 500 650 1000 1200 1700 500 650 1000 1200 1700 0.0047 472 0.0056 562 0.0062 622 0.0068 682 0.01 103 0.012 123 0.015 153 0.018 183 0.022 223 0.033 333 0.039 393 0.047 473 0.056 563 0.068 683 0.082 823 0.1 104 0.15 154 0.18 184 Model 0.22 224 0.47 474 Support customer thermal models for design-in RELEASED © 2019 KEMET Corporation U2J MLCC Development • BME C0G capacitors perform well for WBG applications requiring high bias voltages such as in DC-Link & snubber applications. • For lower bias voltages such as 48V DC-DC power supplies U2J MLCC with Ni BME inner electrodes extend the Class-I capacitance range up to 50V rating. • U2J MLCC properties are similar to C0G making them suitable for low loss switching in resonant LLC designs. • U2J has a small, predictable and linear capacitance change vs temperature. © 2019 KEMET Corporation KEMET U2J Dielectric Relative Capacitance vs. Temperature Class-I Dielectrics (Examples C0G: 0±30ppm/°C vs. U2J: -750±120ppm/°C) © 2019 KEMET Corporation Temperature Rise vs. Ripple Current • BME C0G and BME U2J both show high current carrying capability. • Temperature rise <14°C up to ripple current of 10Arms. © 2019 KEMET Corporation U2J MLCC Range Rated Case Size Case Size Maximum Available Capacitance CAP Increase Voltage (Inches) (mm) vs. current C0G (Vdc) C0G U2J 10 2.2nF 4.7nF +114% 0402 1005 16 / 25 2.2nF 2.2nF - 50 1.5nF 1.8nF +20% 10 15nF 33nF +120% 0603 1608 16 / 25 15nF 15nF - 50 6.8nF 10nF +47% 10 47nF 100nF +112% 0805 2012 16 / 25 47nF 56nF +19% 50 22nF 47nF +114% 16 / 25 100nF 220nF +120% 1206 3216 50 82nF 150nF +83% 16 / 25 220nF 330nF +50% 1210 3225 50 150nF 270nF +80% 1812 4532 50 220nF 470nF +114% Under Development Standard and Flexible Termination © 2019 KEMET Corporation Leadless Stacks Introduction • MLCC terminations are bonded together using Transient Liquid Phase Sintering – Sn, Cu, Ag & Au term.
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  • Selecting and Applying Aluminum Electrolytic Capacitors for Inverter Applications

    Selecting and Applying Aluminum Electrolytic Capacitors for Inverter Applications

    Selecting and Applying Aluminum Electrolytic Capacitors for Inverter Applications Sam G. Parler, Jr. Cornell Dubilier Abstract— Aluminum electrolytic capacitors are widely used in all types of inverter power systems, from variable-speed drives to welders to UPS units. This paper discusses the considerations involved in selecting the right type of aluminum electro- lytic bus capacitors for such power systems. The relationship among temperature, voltage, and ripple ratings and how these parameters affect the capacitor life are discussed. Examples of how to use Cornell Dubilier’s web-based life-modeling java applets are covered. Introduction a knowledge of all aspects of the application environ- ment, from mechanical to thermal to electrical. The goal One of the main application classes of aluminum elec- of this paper is to assist you with selecting the right trolytic capacitors is input capacitors for power invert- capacitor for the design at hand. ers. The aluminum electrolytic capacitor provides a Capacitor ripple current waveform considerations unique value in high energy storage and low device impedance. How you go about selecting the right ca- Inverters generally use an input capacitor between a pacitor or capacitors, however, is not a trivial matter. rectified line input stage and a switched or resonant Selecting the right capacitor for an application requires converter stage. See Figure 1 below. There is also usu- (a) (b) Current Spectrum 2.5 2 1.5 Ck 1 0.5 0 1 10 100 1000 10000 k d=10% d=5% d=2.5% (d) (c) Figure 1: Inverter schematics. Clockwise: (a) block diagram of a typical DC power supply featuring an inverter stage, (b) motor drive inverter schematic shows the rectification stage, (c) typical inverter capacitor current waveforms, (d) relative capacitor ripple current frequency spectrum for various charge current duties (d=Ic/IL ).