<<

Power for Power Applications Munaf Rahimo, Corporate Executive Engineer Grid Systems R&D, Power Systems ABB Switzerland Ltd, Semiconductors CAS-PSI Special course Power Converters, Baden Switzerland, 8th May 2014

© ABB Group May 16, 2014 | Slide 1 Contents

§ Power Electronics and Power Semiconductors

§ Understanding the Basics

§ Technologies and Performance

§ Packaging Concepts

§ Technology Drivers and Trends

§ Wide Band gap Technologies

§ Conclusions

© ABB Group May 16, 2014 | Slide 2 Power Electronics and Power Semiconductors

FWD1 S1 S3 S5

VDC

S2 S4 S6

© ABB Group May 16, 2014 | Slide 3 Power Electronics Applications are …. .. an established technology that bridges the power industry with its needs for flexible and fast controllers DC Transportation AC AC = = M Grid Systems ~ ~

104 HVDC Traction FACTS 103 Power Motor Industrial Drives Supply Drive 102

DeviceCurrent [A] HP 101 Automotive

DC → AC Lighting AC → DC AC(V , , ) AC(V , , ) 100 1 ω1 ϕ1 → 2 ω2 ϕ2 DC(V1) → DC(V2) 1 2 3 4 10 10 10 10 PE conversion employ controllable solid-state referred to as Power Semiconductors Device Blocking Voltage [V] © ABB Group May 16, 2014 | Slide 4 Power Electronics Application Trends

§ Traditional: More Compact and Powerful Systems

§ Modern: Better Quality and Reliability

§ Efficient: Lower Losses

§ Custom: Niche and Special Applications

§ Solid State: DC Breakers, Transformers

§ Environmental: Renewable Energy Sources, Electric/Hybrid Cars

© ABB Group May 16, 2014 | Slide 5 The Revolution

Sub-module section System Valve PIN

Wafer Module IGBT

1947: Bell`s Today: GW IGBT based HVDC systems

© ABB Group May 16, 2014 | Slide 6 Semiconductors, Towards Higher Speeds & Power

§ It took close to two decades after the invention of the solid-state bipolar transistor (1947) for semiconductors to hit mainstream applications

§ The beginnings of power semiconductors came at a similar time with the in the fifties

§ Both lead to the modern era of advanced DATA Kilby`s first IC in 1958 and POWER processing

§ While the main target for ICs is increasing the speed of data processing, for power devices it was the controlled power handling capability

§ Since the 1970s, power semiconductors have benefited from advanced Silicon material and technologies/ processes developed for the much larger and well funded IC applications and markets Robert N. Hall (left) at GE demonstrated the first 200V/35A Ge power in 1952

© ABB Group May 16, 2014 | Slide 7 The Global Semiconductor Market and Producers

© ABB Group May 16, 2014 | Slide 8 Power Semiconductors; the Principle Power Semiconductor

Current flow direction

Switches (MOSFET, IGBT, Thyistor) ()

© ABB Group May 16, 2014 | Slide 9 Power Semiconductor Device Main Functions

Logic Device High Power Device

§ Main Functions of the power device: § Support the off-voltage (Thousands of Volts)

§ Conduct currents when switch is on (Hundreds of Amps per cm2)

© ABB Group May 16, 2014 | Slide 10 Silicon Switch/Diode Classification

Si Power Devices

BiPolar BiMOS UniPolar

Thyristors IGBT MOSFET GTO/IGCT BJT JFET (Lat. & Ver.) (Lat. & Ver.) Triac

§ Current drive § Current drive § Voltage drive § Voltage drive § Voltage drive § up to 10kV § up to 2kV § up to 6.5kV § few 100V § up to 1.2kV

PIN Diode SB Diode

§ up to 13kV § few 100V © ABB Group May 16, 2014 | Slide 11 Evolution of Silicon Based Power Devices

PCT/Diode Bipolar evolving Technologies GTO IGCT evolving

BJT

MOSFET evolving

MOS IGBT Technologies evolving

Ge → Si

1960 1970 1980 1990 2000 2010

© ABB Group May 16, 2014 | Slide 12 Silicon, the main power semiconductor material

§ Silicon is the second most common chemical element in the crust of the earth (27.7% vs. 46.6% of Oxygen)

§ Stones and sand are mostly consisting of Silicon

and Oxygen (SiO2)

§ For Semiconductors, we need an almost perfect Silicon crystal

§ Silicon crystals for semiconductor applications are probably the best organized structures on earth

§ Before the fabrication of chips, the semiconductor wafer is doped with minute amounts of foreign atoms (p “B, Al” or n “P, As” type doping)

© ABB Group May 16, 2014 | Slide 13 Power Semiconductor Processes

§ It takes basically the same technologies to manufacture power semiconductors like modern logic devices like microprocessors

§ But the challenges are different in terms of Device Physics and Application

Critical Min. doping Max. Process Device Dimension concentration Temperature*

1050 - 1100°C Logic Devices 0.1 - 0.2 µm 1015 cm-3 (minutes) 1250°C MOSFET, IGBT 1 - 2 µm 1013 - 1014 cm-3 (hours)

Thyristor, GTO, IGCT 10 -20 µm < 1013 cm-3 1280-1300°C(days) melts at 1360°C

§ Doping and thickness of the silicon must be tightly controlled (both in % range)

§ Because silicon is a resistor, device thickness must be kept at absolute minimum

§ Virtually no defects or contamination with foreign atoms are permitted

© ABB Group May 16, 2014 | Slide 14 Power Semiconductors Understanding The Basics

© ABB Group May 16, 2014 | Slide 15

… without diving into semiconductor physics …

-

1.50

-

1.00

-

0.50 0.00

ionising radiation0.50

1.00 1.50 - - - 20 15 10 10 15 20 - 5 electron “knocked out of orbit” 0 5 E = energy of electron

conduction band 0

band gap 0.5

allowable valance band energy levels 1 nucleus 1.5

core band 2 r = distance from nucleus 2.5 + + + + + + + + +

Si Si

− − − − Conduction Band Conduction Band Conduction Band

− − − Si Si Si Si

− − −

− Valence Band Band Gap −

− Valence Band − − − Si Si Si Si

− − − Valence Band − −

− −

Si Si Metal Semiconductor Insulator (ρ ≈ 10-6 Ω-cm) (ρ ≈ 102…6 Ω-cm) (ρ ≈ 1016 Ω-cm)

Power Semiconductors, S. Linder, EPFL Press ISBN 2-940222-09-6

© ABB Group May 16, 2014 | Slide 16 The Basic Building Block; The PN Junction electric field p-type n-type − − − − − − − − − − − − − − − − + + + + + + + + − − − − − − − − Anode − − − − − − − − + + + + + + + Cathode − − − − − − − − + + + + + + + + − − − − − − − −

junction

+ donors − acceptors holes electrons EC

No Bias EF

EV Forward Bias e P(+)N(-) Space-charge region abolished and a current starts to flow if the external voltage exceeds the “built- h in” voltage ~ 0.7 V Reverse Bias P(-)N(+) Space-charge region expands and avalanche break-down voltage is reached at critical electric field for Si 5 (2x10 V/cm) © ABB Group May 16, 2014 | Slide 17 The PIN Bipolar Power Diode The low doped drift (base) region is the main differentiator for power devices (normally n-type)

Poisson’s Equation for Electric Field

Charge Density

Permittivity

ρ = q (p – n + ND – NA)

© ABB Group May 16, 2014 | Slide 18 Power Diode Structure and Doping Profile The Power Diode in Reverse Blocking Mode

0.000005

Vpt 0.000004 Vbd

0.000003

Current (Amp) 0.000002

I s 0.000001

0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Voltage (Volt)

13 −3/4 Non - Punch Through Breakdown Voltage Vbd = 5.34 ×10 ND −12 Vpt = 7.67 ×10 NDWB Punch Through Voltage

• All the constants on the right hand side of the above equations have units which will result in a final unit in (Volts).

© ABB Group May 16, 2014 | Slide 19 Power Diode Reverse Blocking Simulation (1/5)

1.0E+19 2.1E+05

1.0E+18 1.8E+05

1.0E+17 1.5E+05

1.0E+16 1.2E+05

1.0E+15 9.0E+04

1.0E+14 6.0E+04 Electric Field [V/cm] Field Electric VR=100V

Carrier ConcentrationCarrier[cm-3] 1.0E+13 3.0E+04 Electric Field 1.0E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 20 Power Diode Reverse Blocking Simulation (2/5)

1.0E+19 2.1E+05

1.0E+18 1.8E+05

1.0E+17 1.5E+05

1.0E+16 1.2E+05

1.0E+15 9.0E+04

1.0E+14 VR=1000V 6.0E+04 Electric Field [V/cm] Field Electric

Carrier ConcentrationCarrier[cm-3] 1.0E+13 3.0E+04 Electric Field 1.0E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 21 Power Diode Reverse Blocking Simulation (3/5)

1.0E+19 2.1E+05

1.0E+18 1.8E+05

1.0E+17 1.5E+05

1.0E+16 1.2E+05

1.0E+15 VR=2000V 9.0E+04

1.0E+14 Electric Field 6.0E+04 Electric Field [V/cm] Field Electric

Carrier ConcentrationCarrier[cm-3] 1.0E+13 3.0E+04

1.0E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 22 Power Diode Reverse Blocking Simulation (4/5)

1.0E+19 2.1E+05

1.0E+18 1.8E+05

1.0E+17 1.5E+05

1.0E+16 VR=4000V 1.2E+05

1.0E+15 Electric Field 9.0E+04

1.0E+14 6.0E+04 Electric Field [V/cm] Field Electric

Carrier ConcentrationCarrier[cm-3] 1.0E+13 3.0E+04

1.0E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 23 Power Diode Reverse Blocking Simulation (5/5)

1.0E+19 2.1E+05

1.0E+18 VR=7400V 1.8E+05 IR=1A 1.0E+17 1.5E+05 Electric Field

1.0E+16 1.2E+05

1.0E+15 9.0E+04

1.0E+14 6.0E+04 Electric Field [V/cm] Field Electric

Carrier ConcentrationCarrier[cm-3] 1.0E+13 3.0E+04

1.0E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 24 Power Diode in Forward Conduction Mode

5000

4500

4000 Vf = Vpn +VB +Vnn 3500

3000

2500

Current (Amp) Current 2000

1500 Vo 1/Ron 1000

500

0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 Voltage (Volt)

2kT WB 2 VB = ( ) Base (Drift) Region Voltage Drop q 2La

© ABB Group May 16, 2014 | Slide 25 Power Diode Forward Conduction Simulation (1/5)

1.0E+19 Cathode 1.0E+18 Anode 1.0E+17 e-

1.0E+16 h+ 1.0E+15

1.0E+14

Carrier Concentration [cm-3] 1.0E+13

1.0E+12 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 26 90 80 Forward Conduction Simulation (2/5) 70 60 50

IF [A] 40 30 1.0E+19 20 eDensity 10 hDensity 0 1.0E+18 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 DopingConcentration VF [V] 1.0E+17

1.0E+16

1.0E+15

1.0E+14

Carrier Concentration [cm-3] 1.0E+13

1.0E+12 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 27 90 80 Forward Conduction Simulation (3/5) 70 60 50

IF [A] 40 30 1.0E+19 20 eDensity 10 0 1.0E+18 hDensity 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 DopingConcentration VF [V] 1.0E+17

1.0E+16

1.0E+15

1.0E+14

Carrier Concentration [cm-3] 1.0E+13

1.0E+12 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 28 90 80 Forward Conduction Simulation (4/5) 70 60 50

IF [A] 40 30 1.0E+19 20 eDensity 10 hDensity 0 1.0E+18 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 DopingConcentration VF [V] 1.0E+17

1.0E+16

1.0E+15

1.0E+14

Carrier Concentration [cm-3] 1.0E+13

1.0E+12 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 29 90 80 Forward Conduction Simulation (5/5) 70 60 50

IF [A] 40 1.0E+19 30 20 eDensity 10 hDensity 0 1.0E+18 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 DopingConcentration VF [V] 1.0E+17

1.0E+16

1.0E+15

1.0E+14

Carrier Concentration [cm-3] 1.0E+13

1.0E+12 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 30 Power Diode Reverse Recovery

§ Reverse Recovery: Transition from the conducting to the blocking state Stray Inductance

VDC inductive Diode load (2800V)

IGBT

© ABB Group May 16, 2014 | Slide 31 Reverse Recovery Simulation (1/5)

1E+19 3.5E+05

1E+18 3.0E+05 Anode Cathode 1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05 E-Field [V/cm] E-Field 1E+14 1.0E+05 concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 32 Reverse Recovery Simulation (2/5)

1E+19 3.5E+05

1E+18 3.0E+05

1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05 E-Field [V/cm] E-Field 1E+14 1.0E+05 concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 33 Reverse Recovery Simulation (3/5)

1E+19 3.5E+05

1E+18 3.0E+05

1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05 E-Field [V/cm] E-Field 1E+14 1.0E+05 concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 34 Reverse Recovery Simulation (4/5)

1E+19 3.5E+05

1E+18 3.0E+05

1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05 E-Field [V/cm] E-Field 1E+14 1.0E+05 concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 35 Reverse Recovery Simulation (5/5)

1E+19 3.5E+05

1E+18 3.0E+05

1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05 E-Field [V/cm] E-Field 1E+14 1.0E+05 concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 100 200 300 400 500 600 depth [um]

© ABB Group May 16, 2014 | Slide 36 Lifetime Engineering of Power Diodes

§ Recombination Lifetime: Average value of time (ns - us) after which free carriers recombine (= disappear).

§ Lifetime Control: Controlled introduction of lattice defects è enhanced carrier recombination è shaping of the carrier distribution

ON-state Carrier Distribution

without lifetime control

CONCENTRATION with local lifetime control

DEPTH

© ABB Group May 16, 2014 | Slide 37 Power Diode Operational Modes I I • Reverse Blocking State 25C 125C Vbd • Stable reverse blocking +ve Temp. Co. Vpt • Low leakage current 125C Is IF • Forward Conducting State 25C -ve Temp. Co.

• Low on-state losses Vf V V Forward Characteristics Reverse Characteristics • Positive temperature coefficient • Turn-On (forward recovery) • Low turn-on losses

• Short turn-on time Vpf IF IF Current trr • Good controllability dv/dt dir/dt di/dt VR • Turn-Off (reverse recovery) V dif/dt Voltage f Qrr Voltage • Low turn-off losses Current Vpr Ipr t F • Short turn-off time time time • Soft characteristics Forward Recovery Reverse Recovery • Dynamic ruggedness

© ABB Group May 16, 2014 | Slide 38 Power Semiconductors Technologies and Performance

© ABB Group May 16, 2014 | Slide 39 Silicon Power Semiconductor Device Concepts

1000s of volts 10s of volts PCT IGBT MOSFET Today`s 108 evolving Silicon based

PCT IGCT devices 106

GTO / GCT BJT 104 IGBT and the companion Diode Conversion Power [W] MOSFET 2 In red are devices 10 that are in “design-in life” 101 102 103 104 Conversion Frequency [Hz]

© ABB Group May 16, 2014 | Slide 40 Silicon Power Semiconductor Switches

Technology Device Character Control Type

Bipolar () Low on-state losses Current Controlled Thyristor, GTO, GCT High Turn-off losses (“High” control power)

Bipolar (Transistor) Medium on-state losses Current Controlled (“High” control power) BJT, Darlington Medium Turn-off losses

BiMOS (Transistor) Medium on-state losses Voltage Controlled Medium Turn-off losses (Low control power) IGBT

Unipolar (Transistor) High on-state losses Voltage Controlled (Low control power) MOSFET, JFET Low Turn-off losses

© ABB Group May 16, 2014 | Slide 41 The main High Power MW Devices: LOW LOSSES Gate

p n- p n PCT/IGCT Anode Cathode Gate

n- p n p IGBT Cathode Hole Drainage

Plasma in IGCT for low losses

n p Plasma in IGBT p Concentration n- • PCTs & IGCTs: optimum carrier distribution for lowest losses • IGBTs: continue to improve the carrier distribution for low losses

© ABB Group May 16, 2014 | Slide 42 The High Power Devices Developments

© ABB Group May 16, 2014 | Slide 43 Power Semiconductor Power Ratings

Pheat Tj IGBT chip Tj

Rthjc Insulation and baseplate

Rthcs Rthja Heatsink

Rthsa

ambient Ta

© ABB Group Total IGBT Losses : P = P + P + P May 16, 2014 | Slide 44 tot cond turn-off turn-on Performance Requirements for Power Devices (technology curve: traditional focus) § Power Density Handling Capability:

§ Low on-state and switching losses

§ High operating temperatures

§ Low thermal resistance

§ Controllable and Soft Switching:

§ Good turn-on controllability

§ Soft and controllable turn-off and low EMI

§ Ruggedness and Reliability:

§ High turn-off current capability

§ Robust short circuit mode for IGBTs

§ Good surge current capability § Good current / voltage sharing for paralleled / series devices

§ Stable blocking behaviour and low leakage current

§ Low “Failure In Time” FIT rates

§ Compact, powerful and reliable packaging

© ABB Group May 16, 2014 | Slide 45 Power Semiconductor Voltage Ratings

VDWM VDRM VDSM

VDPM

VRPM VRWM VRRM VRSM

• VDRM – Maximum Direct Repetitive Voltage

• VRRM – Maximum Reverse Repetitive Voltage

• VDPM – Maximum Direct Permanent Voltage

• VRPM – Maximum Reverse Permanent Voltage

• VDSM – Maximum Direct Surge Voltage

• VRSM – Maximum Reverse Surge Voltage

• VDWM – Maximum Direct Working Voltage 6.5kV IGBT FIT rates due to cosmic rays

© ABB Group May 16, 2014 | Slide 46 Cosmic Ray Failures and Testing

§ Interaction of primary cosmics with magnetic field of earth “Cosmics are more focused to the magnetic poles”

§ Interaction with earth atmosphere:

§ Cascade of secondary, tertiary … particles in the upper atmosphere Terrestrial secondary cosmics cosmics § Increase of particle density primary cosmic particle § Cosmic flux dependence of altitude earth

§ Terrestrial cosmic particle species:

§ muons, neutrons, protons, electrons, pions atmosphere § Typical terrestrial cosmic flux at sea level: 20 neutrons per cm2 and h

p n

- +

• Failures due to cosmic under blocking condition without precursor • Statistical process and Sudden single event burnout

© ABB Group May 16, 2014 | Slide 47 Power Semiconductor Junction Termination

Anode Cathode

Metal source contact Passivation Metal source contact Passivation N+ P+ Diffusions Bevel Guard rings N - Base (High Si Resistivity) N - Base (High Si Resistivity) P+ P+ N+ Moly

Planar technology Conventional technology

© ABB Group May 16, 2014 | Slide 48 The Insulated Gate Bipolar Transistor (IGBT)

cut plane

IGBT cell approx. 100’000 per cm2

© ABB Group May 16, 2014 | Slide 49 How an IGBT Conducts (1/5)

Emitter

+

Switch „OFF“: No mobile carriers (electrons or holes) in substrate. No current flow.

Collector How an IGBT Conducts (2/5)

Emitter

+

3.3kV IGBT output IV curves Turn-on: Application of a positive voltage between Gate and Emitter

Collector How an IGBT Conducts (3/5)

Emitter Current flow

The emitter supplies electrons + through the lock into the substrate.

The anode reacts by supplying holes into the substrate

A MOSFET has only N+ region, so no holes are supplied and the device Collector operates in Unipolar mode Current flow How an IGBT Conducts (4/5)

Emitter Current flow

+

Electrons and holes are flowing towards each other (Drift and diffusion)

Collector Current flow How an IGBT Conducts (5/5)

Emitter Current flow Electrons and holes are mixing to constitute a quasi-neutral plasma. With plenty of mobile carriers, + current can flow freely and the device is conducting (switch on)

Collector Current flow 3.3kV IGBT doping/plasma 3.3kV IGBT Switching Performance: Test Circuit Stray Inductance

VDC inductive Diode load (1800V)

IGBT Plasma extraction during turn-off (1/5)

1E+18 3.0E+05 Cathode (MOS-side) 1E+17 2.5E+05 Anode 1E+16 2.0E+05 plasma, e ≈ h

1E+15 1.5E+05 Buffer

1E+14 1.0E+05 [V/cm] E-Field

concentration [cm-3]concentration N-Base (Substrate) 1E+13 5.0E+04

1E+12 0.0E+00 0 50 100 150 200 250 300 350 400 depth [um] Plasma extraction during turn-off (2/5)

1E+18 2.5E+05

1E+17 2.0E+05

1E+16 1.5E+05 1E+15 1.0E+05

1E+14 [V/cm] E-Field concentration [cm-3]concentration 5.0E+04 1E+13

1E+12 0.0E+00 0 50 100 150 200 250 300 350 400 depth [um] Plasma extraction during turn-off (3/5)

1E+18 3.0E+05

1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05

1E+14 1.0E+05 [V/cm] E-Field concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 50 100 150 200 250 300 350 400 depth [um] Plasma extraction during turn-off (4/5)

1E+18 3.0E+05

1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05

1E+14 1.0E+05 [V/cm] E-Field concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 50 100 150 200 250 300 350 400 depth [um] Plasma extraction during turn-off (5/5)

1E+18 3.0E+05

1E+17 2.5E+05

1E+16 2.0E+05

1E+15 1.5E+05

1E+14 1.0E+05 [V/cm] E-Field concentration [cm-3]concentration

1E+13 5.0E+04

1E+12 0.0E+00 0 50 100 150 200 250 300 350 400 depth [um] 3.3kV IGBT Turn-on and Short Circuit Waveforms

IC=62.5A, VDC=1800V 250 2400

200 2000

150 1600

Turn-on 100 1200 Voltage [V] Current [A], 50 800

waveforms Gate-Voltage [V] Collector-Emitter

0 400

-50 0 1.0 2.0 3.0 4.0 5.0 6.0 time [us]

VGE=15.0V, VDC=1800V 450 2500 400 2250 350 2000 300 1750 250 1500 Short 200 1250 150 1000 Voltage [V] Current [A],

Circuit Gate-Voltage [V] 100 750 Collector-Emitter 50 500 0 250 -50 0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 time [us] Power Semiconductors Packaging Concepts

© ABB Group May 16, 2014 | Slide 62 Power Semiconductor Device Packaging

• What is Packaging ? • A package is an enclosure for a single element, an integrated circuit or a hybrid circuit. It provides hermetic or non-hermetic protection, determines the form factor, and serves as the first level interconnection externally for the device by means of package terminals. [Electronic Materials Handbook]

copper plastic housing • Package functions in PE terminal

epoxy

• Power and Signal distribution bond wires metalization

chip gel • Heat dissipation solder substrate base plate • HV insulation

• Protection Power Semiconductor Device Packaging Concepts

“Insulated” Devices Press-Pack Devices

Mounting heat sink galvanically insulated heat sinks under high voltage from power terminals

n all devices of a system can be n every device needs its own mounted on same heat sink heat sink

Failure Mode open circuit after failure fails into low impedance state

Markets Industry Industry Transportation Transportation T&D T&D Power range typically 100 kW - low MW MW transportation components have higher reliability demands Insulated Package for 10s to 100s of KW

Low to Medium Power Semiconductor Packages

Discrete Devices Standard Modules Insulated Modules

• Used for industrial and transportation applications (typ. 100 kW - 3 MW) • Insulated packages are suited for Multi Chip packaging IGBTs

package with semiconductors inside (bolted to heat sink)

power & control terminals heat sink (water or air cooled) Press-Pack Modules

power terminals current flow (top and bottom of module) package with semiconductors inside

heat sink (water or air cooled)

control terminal Power Semiconductors Technology Drivers and Trends

© ABB Group May 16, 2014 | Slide 68 Power Semiconductor Device Technology Platforms active area (main electrode) gate pad (control electrode)

junction termination substrate (silicon) (“isolation of active area”)

© ABB Group May 16, 2014 | Slide 69 Power Semiconductor Package Technology Platforms Heat dissipation Electrical distribution • Interconnections • Interconnections • Advanced cooling concepts • Power / Signal terminals

Pheat Tj IGBT chip Tj • Low electrical parasitics

Rthjc Insulation and baseplate

Rthcs Rthja Heatsink

Rthsa

ambient Ta Typical temperature cycling curve 1.E+8 High Voltage Insulation 1.E+7 Encapsulation/ protection smaller size, lower complexity • Partial Discharges 1.E+6 • Hermetic / non-hermetic • HV insulating 1.E+5 1.E+4 • Coating / filling materials

• Creepage distances 1.E+3 Nº of cycles of Nº 1.E+2

1.E+1 greater size, higher complexity

1.E+0

1.E-1 10 Junction temperature excursion (ºC) 100 Powerful, Reliable, Compact, Application specific

© ABB Group May 16, 2014 | Slide 70 Insulated Press Pack Overcoming the Limitations (the boundaries) The Power

Von Tj,max – Tj,amb Power = Von Ic or = Ron Rth

The Margins

Pmax = Vmax.Imax, Controllability, Reliability

The Application Topology, Frequency, Control, Cooling

The Cost of Performance © ABB Group May 16, 2014 | Slide 71 Technology Drivers for Higher Power (the boundaries) Larger Area Integration I I Area Larger Devices Termination/Active Integration HV, RC, RB Extra Paralleling

New Tech.

Reduced Losses Absolute Increased Margins Carrier Enhancement Increasing Device Power Latch-up / Filament Protection Thickness Reduction (Blocking) Density Controllability, Softness & Scale

V.I V .I New Technologies max max Losses SOA

ΔT/Rth Temperature Traditional Focus Improved Thermal High Temp. Operation

© ABB Group May 16, 2014 | Slide 72 Lower Package Rth The Bimode Insulated Gate Transistor (BIGT) integrates an IGBT & RC-IGBT in one structure to eliminate snap-back effect BIGT Wafer Backside

IGBT Turn-off Diode Reverse Recovery

© ABB Group May 16, 2014 | Slide 73 Wide Bandgap Technologies

ABB SiC 4.5kV PIN Diodes for HVDC (1999)

© ABB Group May 16, 2014 | Slide 74 Wind Bandgap Semiconductors: Long Term Potentials Parameter Silicon 4H-SiC GaN Diamond

Band-gap Eg eV 1.12 3.26 3.39 5.47

Critical Field Ecrit MV/cm 0.23 2.2 3.3 5.6

Permitivity εr – 11.8 9.7 9.0 5.7 2 Electron Mobility µn cm /V·s 1400 950 800/1700* 1800 3 BFoM: εr·µn·Ecrit rel. to Si 1 500 1300/2700* 9000 -3 10 -9 -10 -22 Intrinsic Conc. ni cm 1.4·10 8.2·10 1.9·10 1·10 Thermal Cond. λ W/cm·K 1.5 3.8 1.3/3** 20

* significant difference between bulk and 2DEG ** difference between epi and bulk

§ Higher Blocking § Higher Power § Lower Losses § Wider Frequency Range § Lower Leakage § Very High Voltages § But higher built-in voltage § Higher Temperature

© ABB Group May 16, 2014 | Slide 77 SiC Switch/Diode Classification and Issues

§ Defect Issues SiC Power Devices § High Cost

BiPolar BiMOS UniPolar

Thyristors BJT IGBT JFET MOSFET 5kV~…. 600V~10kV 5kV~…. 600V~10kV 600V~10kV

§ MOS Issues § Bipolar Issues § Bipolar Issues § Bipolar Issues § Normally on § MOS Issues § Bias Voltage § Current Drive § Bias Voltage

Diode Diode 5kV ~ …. 600V~5kV

§ Bipolar Issues

© ABB Group § Bias Voltage May 16, 2014 | Slide 76 SiC Unipolar Diodes vs. Si Bipolar Diode

1700V Fast IGBTs with SiC Diodes during turn-on

Si diode

SiC diodes

© ABB Group May 16, 2014 | Slide 77 Conclusions

§ Si Based Power semiconductors are a key enabler for modern and future power electronics systems including grid systems

§ High power semiconductors devices and new system topologies are continuously improving for achieving higher power, improved efficiency and reliability and better controllability

§ The Diode, PCT, IGCT, IGBT and MOSFET continue to evolve for achieving future system targets with the potential for improved power/performance through further losses reductions, higher operating temperatures and integration solutions

§ Wide Band Gap Based Power Devices offer many performance advantages with strong potential for very high voltage applications

© ABB Group May 16, 2014 | Slide 78