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Next Generation Power Electronics Manufacturing Innovation InstituteFebruary 27, 2014
Research Retreat
D e n n i s K e k a s
I n t e r i m E x e c u t i v e D i r e c t o r ,N e x t G e n e r a t i o n P o w e r E l e c t r o n i c s M a n u f a c t u r i n g I n n o v a t i o n I n s t i t u t e
Year
Empl
oyee
s (th
ousa
nds)
Source: data.bls.gov, Current Employment Statistics Survey
$25,634,942 (18%)State Appropriated FundsChallenge:
Loss of U.S. Manufacturing Employment
Vision: Wide bandgap technology for a more energy efficient world
Mission: Develop a manufacturing-focused innovation ecosystem to reduce cost, improve performance and reliability, and enable U.S. industry dominance in WBG semiconductor devices and systems to create jobs.
Next Generation Power ElectronicsManufacturing Innovation Institute
Applications
Operate above 300 oC compared to 150 oC for Silicon-based devices
Handle 10 timeshigher voltages
Reduce losses during DC-to-AC electricity conversion by 90%
Produce bulbs with 10 times more light that last 30 times longer …
saving $250B by 2030
RD&D
Wafer Suppliers
Deviceand Package
Foundry
PowerElectronicsCompanies
Design House/Device
Manufacture
Founding Partners
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CommercialProduct Acceleration
Production& Packaging
Foundries
Comprehensive Education and
Workforce Development
Program
Research, Development &Demonstration
Thriving Power Electronics Industry
Ecosystem
$25,634,942 (18%)State Appropriated Funds
TALENT:Comprehensive Education andWorkforce Development Program
Summer Institute Training for working professionals Training community college and high school teachers
Undergraduate Research Program
WBG Professional Science Masters
Online WBG University
MEP provided training
ApproachTo
Innovation
WaferSuppliers Market Demand
and Feedback
DeviceDesignHouse
WaferFabs
PackagingFabs
OEMs
600V, GaN HFET
1200V, SiC JBS, MOSFET
1700V, SiC JBS, MOSFET
4500VSiC JBS, MOSFET
10kV, SiC JBS, MOSFET
RFMD
1200V, GaN
Vertical Tr.Avogy
Monolith Semi. &
X-Fab
Monolith Semi. &
X-Fab
USCi
CREE
600V
1200V
1700V
4.5kV
10kV
20kW 75kW
John DeereHeavy Duty EV
Inverter
Toshiba MVD
Toshiba PV Inverter
Toshiba PV Inverter
Toshiba PV Inverter
GridBridgeGrid Energy
Router
DelphiVehicle Traction
Inverter
VaconMedium Voltage
Drive
200kW Power
Voltage
End ProductsDevices
15kV
MARKET DEMAND:Commercial Product Acceleration
Low Voltage Devices
(600V to 1700V) Medium VoltageDevices
(3300V to 6500V)3 years
5 years
High Voltage Devices(> 10kV)
10 years
Achieve last 50%cost reduction viaPower Electronics
InnovationTARGET:WBG CostsReach Parity with Silicon Cost
Parity
Don’t Exist
Currently 10X
Currently 10X
1.5X
• Establish standard testing benchmarks ❶❷❻• Long-term reliability test ❶❷❹❺• Identify physics of failure mechanism ❹❺❻• Develop ruggedness by process/device ❸❹❻
Reliability
• Devices to exploit WBG benefits ❸❹❻• Advanced package development ❶❷❺• Application aligned device choice ❶❷❸• Develop WBG exclusive application ❶❷
Performance
• Improve materials for predictive output ❹❺❻• Larger volume inviting many customers ❶❷❺• Silicon compatible manufacturability ❸❹❻• Novel device, package development ❸❺❻
Cost
1WBG High Power Electronics
2WBG Power Supply
3WBG Device Design
4WBG Device Failure Analysis
5WBG Power Module Failure Analysis & Reliability
6WBG Device Fabrication & Characterization
WBG Service Centers1
High Power Electronics
2Power Supply
3Device Design
4Device Failure Analysis
5Power Module Failure Analysis & Reliability
6Device Fabrication & Characterization
WBG Service Centers
Wide Bandgap Service Centers and Shared RD&D Facilities
Increase reliability
Improve performance
Reduce cost
IP Generation&
TechnologyTransfer
RD&D Thrust AreasCritical GaN Research - Umesh Mishra, Lead
- GaN Ron Scaling- Stability and Reliability- Normally-off mode
Critical SiC Research - Jay Baliga, Lead
- MOS interface quality- Stability and Reliability- Bipolar degradation
Power Electronics - Fred Lee, Lead
- High density converters- Low cost PV inverters- High temperature EV inverters
Packaging - Doug Hopkins, Lead
- High temperature packaging- Low Rth- Low parasitic inductance
NC State Expertise
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NNF, AIF
NSF FREEDM
NC State’s Centennial Campus NCSU Nanofabrication Facility
Analytical Instrumentation Facility
Existing Infrastructure at NC State
NC State Competency: Building Industry Partnerships
Centers & Institutes draw about 180 partners,including some of the top names in industry.
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Transforming Economies
Dennis Kekasresearch.ncsu.edu/power
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