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  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 1

    Hitachi Double-Side Cooling Power Module from Audi e-tron’s InverterHitachi’s power module and its innovative assembling technology of integrated double-side cooling structure.

    22 bd Benoni Goullin44200 NANTES - FRANCE +33 2 40 18 09 16 [email protected] www.systemplus.fr

    SP20516 – POWER report by Amine ALLOUCHELaboratory Analysis by Véronique LE TROADEC

    January 2020 – SAMPLE

    REVERSE COSTING® – STRUCTURAL, PROCESS & COST REPORT

    http://www.systemplus.fr/http://www.systemplus.fr/

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 2

    SUMMARY

    Overview / Introduction 4

    o Executive Summary

    o Market

    o Reverse Costing Methodology

    o Glossary

    Company Profile 9

    o Hitachi Company Profile

    o Hitachi Inverter Technology

    o Supply Chain

    Physical Analysis 14

    o Synthesis of the Physical Analysis

    o Package Analysis

    Package Opening

    Package Cross-section

    o Si IGBT Die

    IGBT Die View & Dimensions

    IGBT Die Process

    IGBT Die Cross-section

    o Si Diode Die

    Diode Die View & Dimensions

    Diode Die Process

    Diode Die Cross-section

    Manufacturing Process 76

    o Si IGBT Fabrication Unit

    o Si IGBT Process Flow

    o Si Diode Fabrication Unit

    o Si Diode Process Flow

    o Final Test & Packaging Fabrication unit

    o Packaging Process Flow

    Cost Analysis 91

    o Synthesis of the Cost Analysis

    o Yields Explanation & Hypotheses

    o Si IGBT

    IGBT Front-End Cost

    IGBT Wafer Cost per Process Step

    IGBT Die Probe Test & Dicing

    IGBT Die Cost

    o Si Diode

    Diode Front-End Cost

    Diode Wafer Cost per Process Step

    Diode Die Probe Test & Dicing

    Diode Die Cost

    o Power Card Cost

    Power Card BOM Cost

    Power Card Assembly Cost

    o Module Cost

    Module BOM Cost

    Packaging Assembly Cost

    Final Module Cost

    Selling Price Analysis 116

    o Definition of prices

    o Estimation of selling price

    Comparison 119

    o Hitachi vs Toyota vs Infineon DSC Power Modules

    Feedbacks 121

    Company Services 123

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 3

    Overview / Introductiono Executive Summaryo Marketo Reverse Costing

    Methodologyo Glossary

    Company Profile & Supply Chain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Executive Summary

    The future of mobility will be electric. The new environmental regulations to reduce average CO2 emissions and automotive trends play in favor of stronger vehicle electrification and faster deployment of Electric Vehicles/ Hybrid Electric Vehicles(EV/HEVs). Yole Développement expects that EV/HEV market in number of vehicles will reach 24 Million units by 2024.

    Vehicles with high electrification can usually benefit from more incentive mechanisms giving an advantage also to the car owner. Increasing battery energy capacity enables longer driving range of electric cars and powerful electric motors enable strong acceleration and high driving pleasure.

    High electric power and needs for inverter downsizing bring challenges on the power module level.

    Innovations at this level concern power module aspect (power card-like power module), baseplate structure (pin fin), the cooling technology (double-side cooling).

    Hitachi combines all these key innovations in its new integrated 3rd generation double-side cooling power module.

    In this 3rd generation double-sided cooling design, Hitachi implements a built-in latest-generation insulated-gate bipolar transistors (IGBTs) and diodes.

    This report presents a deep analysis of the Hitachi power module. Supported by a full teardown of the module’s components and housing, this report reveals Hitachi’s innovative assets to assemble its 3rd generation double-sided cooling package as well as the designs of its IGBT and diode.

    This report includes an estimated manufacturing cost of all the module’s components and its selling price analysis. It proposes a comparison between double sided cooling automotive power modules from Hitachi, Toyota, and Infineon.

    These comparisons highlight differences in the packaging design, dies, and costs.

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 4

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Synthesis of the Physical Analysis

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 5

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Package X-Rays – Terminals Identification

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 6

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Package Cross-Section

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 7

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Package Cross-Section

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 8

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Die Cross-Section – Gate Contact

    Layers thickness:

    o Xxx layer: xx µm

    o Xxx layer: xx µm

    o Gate poly contact width: xx µm

    o Xxx : xx µm

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 9

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Die Cross-Section – EDX Material Analysis

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 10

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Si Diode - Die Dimensions

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 11

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Die Cross-Section – Ring

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 12

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis

    Manufacturing Process Flowo Si IGBT Fab Unito Si IGBT Process Flowo Si Diode Fab Unito Si Diode Process Flowo Packaging Fab Unito Packaging Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    IGBT Process Flow (2/4)

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 13

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis

    Manufacturing Process Flowo Si IGBT Fab Unito Si IGBT Process Flowo Si Diode Fab Unito Si Diode Process Flowo Packaging Fab Unito Packaging Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Module Process Flow

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 14

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysiso Synthesiso Si IGBT Costo Si Diode Cost o Power Card Costo Packaging Costo Module Cost

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    IGBT Wafer Cost Per Process Steps

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 15

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysiso Synthesiso Si IGBT Costo Si Diode Cost o Power Card Costo Packaging Costo Module Cost

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Diode Front-End Cost

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 16

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysiso Synthesiso Si IGBT Costo Si Diode Cost o Power Card Costo Packaging Costo Module Cost

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Power Card – Assembly Cost

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 17

    Overview / Introduction

    Company Profile & SupplyChain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysiso Synthesiso Si IGBT Costo Si Diode Cost o Power Card Costo Packaging Costo Module Cost

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Module – BoM & Assembly Cost

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 18

    Overview / Introduction

    Company Profile & Supply Chain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    Estimated Manufacturer Price

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 19

    Overview / Introduction

    Company Profile & Supply Chain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparisono Hitachi vs Toyota vs

    Infineon Power Modules

    Feedbacks

    Related Reports

    About System Plus

    Hitachi vs Toyota vs Infineon Power Cards

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 20

    Overview / Introduction

    Company Profile & Supply Chain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Plus

    REVERSE COSTING ANALYSES - SYSTEM PLUS CONSULTING

    POWER SEMICONDUCTORS & COMPOUND• Mitsubishi J1- Series 650V High-Power Modules for

    Automotive• Infineon FF400R07A01E3 Double Side Cooled IGBT

    Module• Toyota Prius Power Modules• Infineon CooliR²Die™ Power Module• Automotive Power Module Packaging Comparison 2018

    MARKET AND TECHNOLOGY REPORTS - YOLE DÉVELOPPEMENT

    POWER ELECTRONICS & COMPOUND SEMI• Power Electronics for Electric & Hybrid Electric Vehicles 2020• Status of the Power Module Packaging Industry 2019

    Related Reports

    https://www.i-micronews.com/products/status-of-the-power-module-packaging-industry-2019/https://www.i-micronews.com/products/status-of-the-power-module-packaging-industry-2019/https://www.systemplus.fr/reverse-costing-reports/mitsubishi-j1-series-650v-high-power-modules-for-automotive/https://www.systemplus.fr/reverse-costing-reports/infineon-ff400r07a01e3-double-side-cooled-igbt-module/https://www.systemplus.fr/reverse-costing-reports/toyota-prius-power-modules/https://www.systemplus.fr/reverse-costing-reports/infineon-coolir%c2%b2die-power-module/https://www.systemplus.fr/reverse-costing-reports/automotive-power-module-packaging-comparison-2018/https://www.i-micronews.com/products/power-electronics-for-electric-hybrid-electric-vehicles-2020/https://www.i-micronews.com/products/status-of-the-power-module-packaging-industry-2019/https://www.systemplus.fr/wp-content/uploads/2018/01/SP18375_Infineon_double_side_cooling_IGBT_sample.pdfhttps://www.systemplus.fr/wp-content/uploads/2018/01/SP18375_Infineon_double_side_cooling_IGBT_sample.pdfhttps://www.i-micronews.com/products/power-electronics-for-electric-hybrid-electric-vehicles-2020/https://www.i-micronews.com/products/power-electronics-for-electric-hybrid-electric-vehicles-2020/https://www.systemplus.fr/wp-content/uploads/2018/10/SP18408-Mitsubishi-J1-Serie-650V-Modules_sample-1.pdfhttps://www.systemplus.fr/wp-content/uploads/2018/10/SP18408-Mitsubishi-J1-Serie-650V-Modules_sample-1.pdfhttps://www.systemplus.fr/wp-content/uploads/2016/09/SP16287-Toyota-Prius-PCUs-Power-Modules_sample.pdfhttps://www.systemplus.fr/wp-content/uploads/2016/09/SP16287-Toyota-Prius-PCUs-Power-Modules_sample.pdf

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 21

    COMPANYSERVICES

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 22

    Overview / Introduction

    Company Profile & Supply Chain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Pluso Company Serviceso Contact

    Business Models Fields of Expertise

    Custom Analyses(>130 analyses per year)

    Reports(>60 reports per year)

    Costing Tools

    Trainings

  • ©2020 by System Plus Consulting | SP20516 – Hitachi EV Power Module 23

    Overview / Introduction

    Company Profile & Supply Chain

    Physical Analysis

    Manufacturing Process Flow

    Cost Analysis

    Selling Price Analysis

    Comparison

    Feedbacks

    Related Reports

    About System Pluso Company Serviceso Contact

    Contact

    Headquarters22 bd Benoni Goullin44200 NantesFRANCE+33 2 40 18 09 [email protected]

    Europe Sales OfficeLizzie LEVENEZFrankfurt am MainGERMANY+49 151 23 54 41 [email protected]

    www.systemplus.fr

    NANTESHeadquarter

    FRANKFURT/MAINEurope Sales Office

    LYONYOLE HQ

    TOKYOYOLE KK

    GREATER CHINAYOLE

    PHOENIXYOLE Inc.

    KOREAYOLE

    Asia Sales OfficeTakashi ONOZAWATokyoJAPANT : +81 804 371 [email protected]

    Mavis WANGTAIWANT :+886 979 336 809CN: [email protected]

    America Sales OfficeSteve LAFERRIEREPhoenix, AZWESTERN UST : +1 310 600 [email protected]

    Chris YOUMANEASTERN US & CANADAT : +1 919 607 9839 [email protected]

    mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]