Modern Power Electronic Devices: Physics, applications, and reliability

Power devices are key to modern power systems, performing essential functions such as inverting and changing voltages, buffering, and switching. The increasing complexity of power systems, with distributed renewable generation on the rise, is posing challenges to these devices. In recent years, several new devices have emerged, including wide bandgap devices, each with advantages and weaknesses depending on circumstances and applications. With a device-centric approach, this book begins by introducing the present challenges in Power Electronics, emphasizing the relevance of this discipline in today's scenario, and pointing out the key parameters to pay attention to from the application-design perspective. The next nine chapters dig into details, covering junction diodes, thyristors, silicon MOSFETs, silicon IGBTs, IGCTs, SiC diodes, SiC MOSFETs, GaN metal-insulator-semiconductor field-effect transistors (MIS-FETs), and GaN vertical transistors. A set of three chapters follow, covering key aspects from the designer's standpoint, namely module design and reliability, switching cell design, and IGBT gate-driving methods for robustness and reliability. A chapter outlining the prospects and outlooks in power electronics technology and its market concludes the book. This book addresses power device technology at the design level, by bridging the gap between semiconductor- and materials science, and power electronic applications. It provides key information for researchers working with power electronic devices and for power electronic application designers, and it is also a useful resource for academics and industrial researches working on power electronics at the system level, such as industrial machine designers and robot designers.
Inspec keywords: elemental semiconductors; III-V semiconductors; silicon; silicon compounds; insulated gate bipolar transistors; power MOSFET; network synthesis; power semiconductor diodes; circuit reliability; wide band gap semiconductors; gallium compounds; thyristors
Other keywords: module design; IGBT robustness; module reliability; SiC; junction diodes; IGBT gate driving methods; IGCT; IGBT reliability; power electronics market; silicon IGBT; thyristors; silicon MOSFET; insulated gate bipolar transistor; switching cell design; Si; gallium nitride transistors; GaN; metal-insulator-semiconductor field-effect transistors; silicon carbide diodes; power electronics technology
Subjects: General electrical engineering topics; Electronic circuits; Semiconductor devices; Reliability; General circuit analysis and synthesis methods
- Book DOI: 10.1049/PBPO152E
- Chapter DOI: 10.1049/PBPO152E
- ISBN: 9781785619175
- e-ISBN: 9781785619182
- Page count: 504
- Format: PDF
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Front Matter
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1 Introduction: Power Electronics challenges
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Power Electronics has nowadays become an enabling discipline and has originated thousands of diverse applications. The core of a Power Electronic converter is the Power Electronic device. Power Electronic devices can be classified as uncontrolled, semi -controllable and fully -controllable. According to this classification, and because of the nonideal behavior, e.g. in limited blocking voltage, nonzero on state voltage drop and noninfinite switching speed, many different kinds of power devices have populated the Power Electronics arena in the past five decades.
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2 Junction diodes
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In this chapter, the junction diodes are specified in focus. It is started from the base of PN junction. The concepts of equilibrium and nonequilibrium PN junctions are introduced, together with the ideas ofjunction breakdown and junction capacitance. Then, according to the different reverse recovery characteristics and applications, junction diodes are divided into three categories, including PiN diodes, FSRDs and DSRDs. Their structures, operation principles and characteristics are described. Some typical applications are illustrated. Instability issues are covered, especially the ones related to temperature dependence. Illustrations for SiC-based junction diodes are also provided.
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3 Thyristors
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Thyristor is a four-layered p-n-p-n structure in which the current flow between anode and cathode is triggered by a current pulse into the gate electrode. The gate trigger current flows from a current or voltage source connected between the gate and cathode, altogether forming the gate (control) circuit. If the impedance of the main circuit connected between the anode and cathode allows the flow of anode current higher than the so-called latching current, the thyristor stays in the forward conduction state (ON-state) even after removing the gate current. In other words, thyristor can be triggered to the ON-state by a current pulse containing a sufficient integral charge and remain ON as long as the anode current is higher than the socalled holding current.
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4 Silicon MOSFETs
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Using both, the Superjunction principle and the shielded -gate concept, silicon MOSFETs have been able to break the limit line of one-dimensional pn-junctions. Continuous progress along technology nodes has created tremendous advantages both in terms of area -specific on -resistance as well as in terms of switching figure of -merits, such as R on *E oss , R on *Q oss and R on *Q gd . Future research work will further enhance the capabilities of silicon MOSFETs and will secure a significant portion of the market for the technology. Widebandgap devices based on SiC or GaN will complement and enhance the technology portfolio of silicon MOSFETs.
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5 Silicon IGBTs
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Chapter 5 covers silicon-based IGBT devices with a focus on device structure, operation, performance requirements and development trends. First, a brief historical background is presented covering the conception and evolution of the IGBT structure from the basic principles of the unipolar power MOSFET and bipolar power transistor. This is followed in Section 5.2 with a detailed explanation of the basic IGBT structure and principle of operation from both the device physics and equivalent circuit model viewpoints. Sections 5.3 and 5.4 cover the basic static and dynamic characteristics of the IGBT. The static characteristics discuss the forward and reverse bias modes of operation while also including the transfer characteristics for the IGBT MOS cell structure. The dynamic performance is explained for both the turn-on and turn-off periods with the help of the internal IGBT capacitive effects and excess carrier charge dynamics during the switching transients. Section 5.5 is focused on the main requirements of the IGBT with respect to mainstream applications and how such demands have influenced the device structural evolution over the years. A number of critical design and performance tradeoff relationships are presented with respect to the structural changes made at both MOS cell (planar, trench) and bulk design (PT, NPT) and their impact on the total device losses, switching control and robustness. Sections 5.6 and 5.7 present the IGBT requirements and design considerations for increasing the device SOA under both short circuit fault mode and switching transients. The different failure modes occurring under such conditions and their causes are discussed and analysed while highlighting the device design impact for providing wider margins and more robust behaviour. Section 5.8 provides the reader with an overview of the IGBT current and future development trends. The main target is to provide continuous increments in power handling capability through a number of independent and often combined technology paths. This includes the traditional trend with a focus on reduced losses and increased margins and new trends with respect to device integration, such as for reverse conducting IGBTs and allowing operation at increased junction temperatures.
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6 IGCTs
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The integrated gate-commutated thyristors (IGCTs) are the latest of the high-power turn-off devices (ToDs). It is a further development of the gate turn-off (GTO) thyristor, which, as the name indicates, is a thyristor capable of being turned-offby gate-control, as will be discussed later (Section 6.4). Thyristors (see Chapter 3) are the most `powerful' of semiconductors, as measured in terms of rated current multiplied by rated voltage but they lack the ability to be turned off while in full conduction, as can, for instance, transistors. This chapter will attempt to cover every important aspect of IGCTs and as most aspects are imbricated, the reader will be referred back and forth to the various sections to avoid repeating earlier explanations, in the hope and belief that this will impart clarity more than frustration.
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7 Silicon carbide diodes
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In Section 7.2, the authors present the most common SiC SBD device structures and discuss their properties important to applications. Section 7.3 is concerned with diode edge termination structures and their reliability and Section 7.4 covers electrical and thermal device properties. In Section 7.5, we present some example applications and demonstrate the advantages of SiC SBDs over their bipolar silicon counterparts. Finally, we conclude with some remarks about possible future developments in Section 7.6 (integration into switches).
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8 SiC MOSFETs
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Modern switching components for energy processing widely consist of active semiconductor devices in Si, a mature and well-established technology that is reaching its physical limits. The main limitations of Si concern the blocking voltage capability, the switching frequency, and the operating temperature. Depending on the voltage range, Si metal-oxide-semiconductor field-effect transistors (MOSFETs) and Si insulated-gate bipolar transistors (IGBTs) are the most common switches adopted for voltage ratings up to 10 kV. More in detail, Si MOSFETs are available for voltage lower than 600 V (super junction (Si) technology), while Si IGBTs are widely adopted for applications in a voltage range from 600 V up to 10 kV. While the Si MOSFET technology is still suitable for applications up to 600 V, the high switching frequency requirements coming from the market are pushing for the development of faster switching devices for the voltage range from 600 V to 10 kV. The main drawbacks of the Si IGBTs, commonly used in this range, are the very high on-state voltage drop and the switching losses, because of the bipolar nature of these devices.
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9 GaN metal-insulator-semiconductor field-effect transistors
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The recent progress and primary challenges in GaN power devices are reviewed and discussed in this chapter. The interface/border trapping at/near the dielectric/ GaN interface in MIS-gate GaN transistor, as well as the hole deficiency in p-GaN HEMT with a Schottky gate, could result in the gate instability issue. The negatively charged states in the gate region would cause a positive VTH shift, whereas the reduced gate overdrive voltage (VG _ ON-VTH ) at a preset VG_oN value could lead to the dynamic RoN increase. The gate instability -induced dynamic RON degradation can be alleviated with a sufficient gate overdrive. For normally-off MIS-gate GaN transistors, the gate instability-induced dynamic RoN can be further reduced by increasing the channel mobility in the recessed gate region and reducing the channel resistance. A monolithically integrated gate driver is desirable from the perspective of gate reliability for p-GaN HEMT with limited gate drive headroom. Meanwhile, bulk trapping in the III-nitride buffer stack could also cause dynamic RON degradation in GaN-on-Si devices. The buffer-related dynamic RoN degradation can be suppressed by compensating the negative buffer traps with hole injection, or through buffer stack optimization with carefully introduced positive charges. On the other hand, the emerging vertical GaN-on-GaN power devices are capable of delivering superior dynamic performance, owing to the low susceptibility of the vertical current path to surface trapping and the minimized bulk trapping in the high-quality homo-epitaxial GaN drift layer with precisely controlled background/compensation impurities.
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10 Gallium nitride transistors: applications and vertical solutions
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Gallium nitride (GaN)-based transistors are among the most promising candidates to substitute Si-based solutions in the 600-1,200 V range of applications. This chapter starts with a brief introduction to the main advantages of GaN-based power transistors over those based on silicon or other wide bandgap materials. The main market segments where GaN power devices could have a significant share in the near future will be discussed. GaN lateral devices will be briefly presented. The chapter will then dwell on the vertical GaN technology discussing all the currently available solutions, their advantages, and their limitations.
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11 Module design and reliability
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Reliability is a core requirement for semiconductor devices in power energy switching applications. In this chapter, reliability-oriented design, simulation, packaging material and process have been covered, especially for high voltage, high current and high power density semiconductor devices.
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12 Switching cell design
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In this chapter, strategies were shown how to adapt packaging technologies to catch up with improving semiconductor properties. Defining the switching cell as the "heart" of power electronic circuits with the highest changes in voltage and current and integrating it helps to influence and design parasitic electromagnetic properties intentionally. In the examples shown above, an optimization of the geometric setup of switching cells is demonstrated using advanced manufacturing technologies and at the same time fulfilling practical requirements for electric, thermal, and mechanics interfaces. The layout rules given for low inductance design in the gate loop and DC link are proven to allow the fastest switching. The examples shown above give an impression on a possible solution for next -generation switching cells and the adaption of different aspects of these solutions in commercial production will remain interesting to observe.
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13 Modern insulated gate bipolar transistor (IGBT) gate driving methods for robustness and reliability
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This chapter has presented an overview of state-of-the-art advanced gate driver techniques for enhancing the reliability of IGBT modules. Broadly speaking, methods can be classified in detection methods, optimization methods, and protection methods. Additionally, optimization and protection methods can be roughly classified in simple (and cheap) and advanced (even more expensive). Simple methods, like the open -loop and passivity -based ones, perform well in normal applications, but advanced methods, like closed -loop control strategies, even if more expensive, are necessary for special applications, like high -power IGBT modules. In the near future, benefiting from the increase of data processing speed and reducing the cost of digital controllers, the advanced techniques discussed in this chapter could become more and more affordable and popular, even in low-cost applications, for both considerably reducing short-term and long-term reliability issues. In fact, basing on a large number of different failure mechanisms, more and more complex strategies will be needed including most of the mature detection and protection methods toward the so-called reliability -oriented gate driver design.
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14 Prospects and outlooks in power electronics technology and market
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Since its introduction with the first transistors, the power electronics market has been driven by technology innovations, consumer needs, political choices, and environmental issues. After the two first megatrends of industrial and renewable energy sources sectors, the power electronics market of the near future will be driven by the automotive sector. The automotive, and the EV/HEV market, not only will impact the vehicles' ecosystem, but also renewable energy, energy storage, and transportation systems, data centers, radar and LiDAR systems, together with other supporting technologies. In this context, we will expect, not only an increase of the market share of IGBT power modules and stabilization of the Si MOSFETs market but in particular new design and materials of power module packaging and WBG-based devices. Moreover, the complete supply chain will be reshaped, with new players, system integrators, and OSAT entering the market of semiconductors.
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Back Matter
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