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Low Thermal ResistanceIGBT Structure
Daniel Benhammou Email: [email protected] Phone:303-275-4458 National Renewable Energy Laboratory
Vahab Hassani (NREL)
FY05 Budget: $ 400K FY06 Budget: $ 500K Project Duration: FY05 to FY06
FreedomCAR APEEM FY05 Wrap-up/FY06 Kick-off Meeting Oak Ridge National Laboratory National Transportation Research Center
November 2, 2005
November 2, 2005 FreedomCAR FY05 Wrap-up/FY06 Kick-off 2
Where Does This Project Fit?
Power
Electronics
Electrical
Machines
Thermal
Systems
Wide Band-Gap Mat’ls
High-Temp. Capacitors
Wide Band-Gap Mat’ls
High-Temp.Capacitors
Magnets
Reduce Thermal Resistance
Air Cooling105C and 85C WEG
Increase Heat-Transfer Coefficient
Low Thermal Resistance IGBT Structure
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What is This Project? • Maximize heat transfer from IGBT structures by
removing layers of greatest thermal resistance. By doing this, we can cool inverter power electronics by means of jet impingement cooling directly on DBC.
November 2, 2005 FreedomCAR FY05 Wrap-up FY06 K ck-off
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Technical Approach
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Design Process
Layout
geomoetry
Modify
Geomoetry
Hand
calculations
Fabricate
Prototype
Design
Simulation
Experimentation
Legend
Computer Model
Physical Model
YES
YES
NO
NO
Run
performance
experiments
Analyze
failure criteria
Needs
Revising?
YES
NO
Import
GeometryGenerate Mesh
Q uality
Mesh?Refine Mesh
Apply Boundary
ConditionsSolve Model
Converged
Results?
Meets
Design
Criteria?
NO
NO
YES
YES
Validate
Simulation
Data
Design
Complete
New Design?
Meets
Design
Criteria?
NO
YES
November 2, 2005 FreedomCAR FY05 Wrap-up FY06 K ck-off
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Technical Approach
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Positives • i
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Negatives • Ti i
How do we address positives and negatives?
November 2, 2005 FreedomCAR FY05 Wrap-up FY06 K ck-off
Mode ng capab ty a ows mu e des gn rev ons thout the h gh cost of fabr cat on and exper menta
va dat on.
Low therma res stance IGBT structures prov de a cost effect ve so ut on to meet DOE program goa s.
Cost Effect ve
Fewer phys caprototypes
Mu e des gn terat ons and numer ca mode s resuonger ead t me to f rst run prototypes. me Consum ng
Design
Simulation
Experimentation
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Goal
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November 2, 2005 FreedomCAR FY05 Wrap-up FY06 K ck-off
Reduce therma res stance between con d e and coo ant
Produce a fu y operat ng prototype ready for commerc zat on
105°C inlet temperature
125°C maximum die temperature
Heat flux: 200 W cm
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Approach for FY05
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November 2, 2005 FreedomCAR FY05 Wrap-up FY06 K ck-off
Estab sh ndustry partner
Mode phys cs Structura analysis
Therma analysis
CFD simulations
6 res stor proof of concept
Iterate des gn
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Major Accomplishments for FY05
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November 2, 2005 FreedomCAR FY05 Wrap-up FY06 K ck-off
CRADA n p ace w th Sem kron
Numer ca mu at ons corroborate feas ty of cut-through IGBT structure
Exper menta gh Heat F ux (HHF) test oop bu t for exper menta va dat on
Current n 8th generat on of des gn
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Low Thermal Resistance IGBT Structure
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November 2, 2005 FreedomCAR FY05 Wrap-up FY06 K ck-off
Cross Section of IGBT Considered
Case A : Solid Spreader Plate
Case B : Spreader Plate with Square Holes
Therma grease
So der
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Conventional IGBT Structure
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0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
Distance from Top of IGBT, mm
Te
mp
., C
Conventional IGBT Structure
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Low Thermal Resistance IGBT Structure
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Low Thermal Resistance IGBT Structure
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0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 Distance from top of the IGBT
f
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Temp. for cut thru
Temp. or cut thru
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Exploded view of design
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– Refinement needed in areas of steep gradients
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Finite element mesh of Semikron inverter phase
Mesh must represent physicabody
Optimize mesh to reduce computation time
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Structural Analysis
• – Applied
– Thermally induced
• – T = 125
– T if = -40
– P = 15 MPa
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Analyze stress
Boundary conditions
ref °C
un °C
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Thermal Analysis
• – Inlet Temp: 105
– hj =65,000 W/m2
– h ll 2
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• – O-ring overlaps IGBT
– Diminishes cooling capability
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Boundary Conditions °C
et °C
wa =15,000 W/m °C
Max Temp: 142.2°C
Why?
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Proposed modification
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– O-ring no longer blocks flow
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DBC extended 5mm
Increased cooling
ux: 100 W cm^2
In et: 105°C
Max Temp: 125.8°C
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CFD modeling
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Single multiple jets
Visualize flow paths Identify problematic geometry
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Approach for FY06
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Comp ete 6-res stor exper ments
Fabr cate 1st prototype heat exchanger ate for exper menta va dat on
Cont nue to opt ze conf gurat on Jet dimensions
Nozzle configurations
Impingement geometry
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Semikron heat exchanger plate
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Integrated heat exchanger plate
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Timeline for FY06
FY06
Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep
Build / test small scale IGBT Structure
Build / test 1st generation prototype Complete
Laboratory Testing
Analyze experimental data
Modify design as requ
uild / tes
ired Functional Prototype Inverter
B t generation 2
Deliver final design
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Key task Milestone/ Deliverable
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Barriers/Challenges
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• Cast parts
• Minimize machining time
• Minimize components
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Fabr cat on cons derat ons Cost effective manufacturing solutions
Mater ts
Eros on
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Interactions and Collaborations
• NREL • Design, model, test
components
• Semikron • Assemble Prototype
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National Labs Universities Industry Partners
Questions