500C/3.8 kW-class Resonant-Mode Power Converter featuring SiC Super Junction Transistors

Capitalizing on a potent confluence of expertise in III-Nitride epitaxy, GaN-Si power device designs, and wide-bandgap power electronics, researchers at GeneSiC Semiconductor and Cornell University jointly propose a SBIR program focused on the development of 15 kW/300 �C-rated power converters using AlGaN/GaN-Si MOS-HFETs and Schottky rectifiers. The proposed AlGaN/GaN-Si power converters to be developed in this program will usher in a new generation of high-efficiency, low-cost, and radiation-hard power conversion units on-board future NASA spacecraft. Phase I of this proposed work will focus on the optimization of the design and fabrication of the AlGaN/GaN-Si MOS-HFET and NSJ SBR devices. Phase II will be focused on the design and integration of Si/GaN gate-drive circuitry with the power SBRs and transistors to create high-power integrated circuits. Another major objective during Phase II will be the construction of Rad-Hard packaging for the power ICs. At the end of Phase II of this program, a fully-functional 15 kW/300�C rated power converter IC equipped with AlGaN/GaN-on-Si MOS-HFETs, Natural SuperJunction (NSJ) SBRs as free-wheeling diodes and on-chip SiC or III-Nitride gate drive circuitry will be demonstrated at a switching frequency of ≥ 1 MHz and at a temperature of ≥ 300 �C. As compared to the existing state-of-the-art power electronics technology, the proposed AlGaN/GaN-on-Si power converters will offer (A) Lower on-state losses, 300 �C operation and 1 MHz switching capability (B) A Lateral device architecture, which is highly desirable for construction for monolithic power integrated circuits (C) Possibility of hybrid interconnection of III-Nitride Power Devices with on-chip Rad-Hard AlGaN/GaN Gate Drive Circuitry (D) Desirable Normally-OFF Power Switches.

The technology developed here is fundamental to a wide range of NASA PMAD and motor control applications. For DC-DC converters, the power ICs developed in this program will connect power sources in a wide variety of NASA mission systems with power sources as Solar arrays, Brayton rotating unit, stirling radioscopes, and fuel cells with various loads like electric propulsion, communications systems, instruments and actuators. The radiation-hardness, high-temperature capability, fast switching speeds, compact form factor and low mass offered by the proposed AlGaN/GaN-on-SiC power integrated circuit will be invaluable for future NASA science missions. A power IC is also the building block for the interface between energy storage devices like batteries and flywheels with the energy sources and loads. Switchmode power supplies improved by high frequency, high temperature power switch is critical for NASA synthetic aperture RADAR's (SAR) antenna array T/R modules. T/R modules typically operate in a pulsed mode, drawing current pulses from a power supply on a periodic basis determined by the operation of the overall RADAR system. The ripple in the output voltage of the T/R module power supply impacts the performance of the RADAR system.

The specifications of the power switch to be developed in this program are ideally suited for most Air Force applications. This includes propulsion system externals like actuators, pumps, and starters, weapons ejection, fuel transfer, lighting, avionics, RADAR, landing gears & breaks, steering, powered doors and ramps, gun drives, anti-icing, environmental control and auxiliary emergency power systems. Conventional bus voltage of military and commercial aircrafts is 270 V, which requires a 600 V power switch to be developed in this program. The realization of a high power density switchmode power supplies and DC-DC conversion circuits will benefit Army's Future Combat System (FCS) by offering it an important part of the subsystem. An electric and hybrid vehicle technology directly affects the M113 APC, Bradley infantry fighting vehicle, HMMWV, 5-ton M939A1 truck, AAAV, 50-ft personnel boat and a more electric aircraft by making them highly deployable, sustainable, survivable, lethal and affordable. An integrated electric power system made using SiC high power devices will increase component placement flexibility within vehicles, double fuel economy by continuously operating smaller engines under optimum conditions, and reduce armor protected volume. It will also enable an increased acceleration and maneuverability due to immediate torque to the wheels or tracks, reduce vehicle thermal and acoustic signatures and reduce system cost and logistics requirements.

This is early/mid-stage (TRL 6) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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