High Temperature Modular Integrated SiC Power Converter Platform

In this work we will develop and prototype a SiC integrated power conversion modular platform for electronics that can operate at very high temperature (500C). The platform is for NASA to use in its space vehicles and rovers to provide power to a set a different instruments and actuators from a single main DC bus line and convert it to the various other DC levels that are required by the different instruments in the vehicle. In addition, the DC-DC power converter platform will be built so that its constituent electronics are able to operate at temperature up to 500C. To enable such high temperature operation, instead of using standard silicon, which fails at approximately 250C, we are using the nascent wide bandgap semiconductor silicon-carbide (SiC) technology. CoolCAD Electronics has developed and patented fabrication methods for SiC that are enabling the construction of electronics that can operate at these high temperatures. In addition, in collaboration with the Power Electronics Group at Arizona State University, we are building entire DC-DC converter systems that can of function in these extreme environments. This requires not only building the high temperature chips and transistors, but we are also building the printed circuit boards with appropriate chip packaging, as well as novel inductors and capacitors that can reliably withstand these temperatures. In addition, we are designing the electronic circuits to be modular and scalable so that the components can be cost effectively used in a variety of applications by paralleling individual power half-bridges as well as complete half bridge modules. Finally, special circuit topologies are being developed that will allow for use of inductive and capacitive components that are realizable for very high temperature operation. In Phase 1, we developed some of these high temperature capabilities; in Phase 2, we will extend this work to develop a complete high temperature DC-DC modular power converter system. We will  develop and prototype a SiC integrated power conversion modular platform for electronics that can operate at high temperatures up to 500C. The platform is for NASA spacecraft and rovers to provide power to a set of different instruments and actuators from a single main DC  bus line and convert it to the various other DC levels as required by the different instruments in the vehicle. To enable high temperature operation, instead of using silicon, which fails at about 250C, we use semiconductor silicon-carbide (SiC). Our patented fabrication methods for SiC are enabling the construction of electronics that can operate at 500C. We design the circuits to be modular so that the components can be used in a variety of applications by paralleling individual components. New circuit topologies are being developed that will allow for use of inductive and capacitive components that are realizable for very high temperature operation. We will prototype the entire system, using SiC transistors and chips, as well as new high temperature capacitors, inductors and printed circuit boards.   Technical Objectives: Design and prototype SiC high temperature DC-DC power converters. The converters will be able to operate in harsh environments and at temperatures as high as 500C. The converters will be modular so that they can be paralleled to cost-effectively satisfy a variety of load requirements. The electronic components, including power transistors, half-bridges and integrated circuits, will be fabricated with the semiconductor SiC using CoolCAD’s proprietary technology. These new SiC transistors and chips, and new capacitors, inductors and printed circuit boards, will be utilized in the design and prototyping a complete high temperature modular boost-buck converter for power distribution on spacecraft and robots in harsh environments.   Deliverables: Prototype of High Temperature (High-T)  SiC-based 720W rated modular High DC-DC buck-boost converter High-T air-core inductor  and Capacitor High-T SiC Integrated LDMOS Power  Bridge Module High-T SiC Power Bipolar Junction Transistor High-T Printed Circuit Board   Work Plan Task 1: Device and System Level Modularity in High-T SiC Power Converters: Design and Protytpe Task 2: Integrated High-T Power Devices and Modules: Design and Fabrication of LDMOS, BJT and Driver ICs Task 3: Converter Design for  High-T Optimal Value Passive Components Task 4: Fabrication of High-T Passive Components Task 5: High-T Circuit Boards and Packaging  

Harsh environment SiC power converters have wide cost-effective applications in (a) spacecraft power management, (b) DC distribution systems in Venus/Mercury/Mars exploration, (c) motor drives, inverters and power supply derivatives in the Space Station, satellite power systems, and (d) motor drives in 'more electric' technology applied to spacecraft and space vehicles. SiC technology finds applications in harsh environments for SiC based control and driver integrated circuits and sensors, where regular Si technology cannot operate. Applications of high temperature (500C) harsh environment SiC power electronics include: (a) automotive engine control and exhaust monitoring (b) power management systems in ground and aerospace vehicles (c) electrical actuator and motors drives in jet engines, (d) geothermal energy monitoring, (e) smart high-temperature sensors, (f) controls for furnaces, gas turbines and nuclear power plants.

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