Design and Development of a Low Cost, Manufacturable High Voltage Power Module for Energy Storage Systems

In this project, APEI, Inc. will design and develop a high performance, high voltage SiC MCPM that is low cost, manufacturable, reliable and reworkable. The target utility scale energy storage applications include power conversion systems for grid-tie, solar array, wind turbine, and vehicle-to-grid to aid in load leveling, frequency control, voltage fluctuations in order to improve the overall power quality and reliability. Presently, most power conversion systems are based on Si IGBTs. However, due to the unique capabilities of SiC and advancement of power converter packaging, this work has the potential to aid in the emergence of smarter, seamless powered grids with less of a dependence on inefficient peak power plants. Phase I will focus on proving feasibility by developing a novel multi-chip wire bondless press contact packaging approach followed by a prototype package demonstrator using high voltage SiC power die. In addition, the thermal, mechanical, and electrical characteristics of the packaging concept will be modeled using three-dimensional finite element analysis as well as SPICE and parasitic extraction software. At the conclusion of Phase I of this project, a high voltage, multi-chip power module will be designed as an effort to easily transition into Phase II which will consist of building the prototype module. APEI, Inc.s packaging design capabilities coupled with module fabrication expertise make it an ideal candidate to develop the advanced high voltage power module proposed in this work.