Power Semiconductors for Power Electronics 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 switches 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 Semiconductor Revolution
Sub-module section System Valve PIN
Wafer Module IGBT
1947: Bell`s Transistor 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 integrated circuit 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 diode 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 Rectifiers (MOSFET, IGBT, Thyistor) (Diodes)
© ABB Group May 16, 2014 | Slide 9 Power Semiconductor Device Main Functions
Logic Device High Power Device
§ Main Functions of the power device: Switch § 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 (Thyristor) 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