A PCB-embedded 1.2 kV SiC MOSFET half-bridge package for a 22 kW AC–DC converter

JS Knoll, G Son, C DiMarino, Q Li… - … on Power Electronics, 2022 - ieeexplore.ieee.org
JS Knoll, G Son, C DiMarino, Q Li, H Stahr, M Morianz
IEEE Transactions on Power Electronics, 2022ieeexplore.ieee.org
This article presents the design and analysis of a double-side-cooled printed circuit board
(PCB) embedded silicon carbide (SiC) MOSFET half-bridge package with low loop
inductances and an integrated gate driver. The 1.2 kV SiC MOSFET dies used in the half-
bridge package are embedded in the PCB using AT&S's patented technique. The dies are
cooled and electrically connected to traces in the PCB through copper-filled microvias. The
design methodology accounts for both electrical and thermal performance, limiting the …
This article presents the design and analysis of a double-side-cooled printed circuit board (PCB) embedded silicon carbide (SiC) MOSFET half-bridge package with low loop inductances and an integrated gate driver. The 1.2 kV SiC MOSFET dies used in the half-bridge package are embedded in the PCB using AT&S's patented technique. The dies are cooled and electrically connected to traces in the PCB through copper-filled microvias. The design methodology accounts for both electrical and thermal performance, limiting the power-loop inductance to 2.3 nH and the maximum package temperature to less than the 175 °C limit. The integration of the gate drive circuitry allows for a high power density and 2.2 nH gate-loop inductances. At 0.12 K/W, the measured junction-to-case thermal resistance with double-sided cooling is 57% lower than that of a TO-247 package. Under similar operating conditions, the PCB-embedded half-bridge package also achieves a 5.6 times lower voltage overshoot and a 0.5% higher peak efficiency than a TO-247-based half-bridge. This article reports the first demonstration of PCB-embedded 1.2 kV SiC MOSFET packages in buck, boost, and ac–dc converters. The prototype three-phase ac–dc converter for an electric vehicle on-board charger is composed of six PCB-embedded half-bridge packages and achieves an efficiency of 98.2% and a power density of 182 W/in 3 .
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