30-kW All-SiC Inverter with 3D-Printed Air-Cooled Heatsinks for Plug-In and Full Electric Vehicle Applications

Chinthavali, Madhu Sudhan; Wang, Zhi Qiang

doi:10.4028/www.scientific.net/MSF.924.845

Title: 30-kW All-SiC Inverter with 3D-Printed Air-Cooled Heatsinks for Plug-In and Full Electric Vehicle Applications

Abstract

This paper presents the design and development of a 30-kW 3D printed based air-cooled silicon carbide (SiC) inverter for electric vehicle application. Specifically, an all-SiC air-cooled power module is designed, aiming at reduced thermal resistance for high temperature and high power density operation. The module assembly incorporates three major parts: an optimized 3D printed heat sink, a SiC MOSFET phase leg module, and a two-channel gate driver. The electrical and thermal performance of the power module is evaluated through double pulse test and continuous operation. Based on the air-cooled power module, a three-phase half-bridge voltage source inverter with 3D-printed air duct is built and tested to further verify the performance of the power module.

Authors:

Chinthavali, Madhu Sudhan ^[1]; Wang, Zhi Qiang ^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Publication Date:: Fri Jun 01 00:00:00 EDT 2018

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

OSTI Identifier:: 1474508

Grant/Contract Number:: AC05-00OR22725

Resource Type:: Accepted Manuscript

Journal Name:: Materials Science Forum (Online)

Additional Journal Information:: Journal Name: Materials Science Forum (Online); Journal Volume: 924; Journal Issue: 1; Journal ID: ISSN 1662-9752

Publisher:: Trans Tech Publications

Country of Publication:: United States

Language:: English

Subject:: 33 ADVANCED PROPULSION SYSTEMS

Citation Formats


                    Chinthavali, Madhu Sudhan, and Wang, Zhi Qiang. 30-kW All-SiC Inverter with 3D-Printed Air-Cooled Heatsinks for Plug-In and Full Electric Vehicle Applications.  United States: N. p., 2018. 
Web.  doi:10.4028/www.scientific.net/MSF.924.845.

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                    Chinthavali, Madhu Sudhan, & Wang, Zhi Qiang. 30-kW All-SiC Inverter with 3D-Printed Air-Cooled Heatsinks for Plug-In and Full Electric Vehicle Applications.  United States.  https://doi.org/10.4028/www.scientific.net/MSF.924.845

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                    Chinthavali, Madhu Sudhan, and Wang, Zhi Qiang. Fri .  
"30-kW All-SiC Inverter with 3D-Printed Air-Cooled Heatsinks for Plug-In and Full Electric Vehicle Applications".  United States.  https://doi.org/10.4028/www.scientific.net/MSF.924.845.  https://www.osti.gov/servlets/purl/1474508.

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@article{osti_1474508,

  title        = {30-kW All-SiC Inverter with 3D-Printed Air-Cooled Heatsinks for Plug-In and Full Electric Vehicle Applications},

  author       = {Chinthavali, Madhu Sudhan and Wang, Zhi Qiang},

  abstractNote = {This paper presents the design and development of a 30-kW 3D printed based air-cooled silicon carbide (SiC) inverter for electric vehicle application. Specifically, an all-SiC air-cooled power module is designed, aiming at reduced thermal resistance for high temperature and high power density operation. The module assembly incorporates three major parts: an optimized 3D printed heat sink, a SiC MOSFET phase leg module, and a two-channel gate driver. The electrical and thermal performance of the power module is evaluated through double pulse test and continuous operation. Based on the air-cooled power module, a three-phase half-bridge voltage source inverter with 3D-printed air duct is built and tested to further verify the performance of the power module.},

  doi          = {10.4028/www.scientific.net/MSF.924.845},

  journal      = {Materials Science Forum (Online)},

  number       = 1,

  volume       = 924,

  place        = {United States},

  year         = {Fri Jun 01 00:00:00 EDT 2018},

  month        = {Fri Jun 01 00:00:00 EDT 2018}

}

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Journal Article:

Free Publicly Available Full Text

Accepted Manuscript (DOE)

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https://doi.org/10.4028/www.scientific.net/MSF.924.845

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Figures / Tables:

Fig. 1: Phase leg power module with the optimized heat sink.

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Works referenced in this record:

Development of a board-level integrated silicon carbide MOSFET power module for high temperature application
conference, May 2015

Wang, Zhiqiang; Shi, Xiaojie; Tolbert, Leon M.
2015 IEEE International Workshop on Integrated Power Packaging (IWIPP)
DOI: 10.1109/IWIPP.2015.7295994

Forced-Air-Cooled 10 kW Three-Phase SiC Inverter with Output Power Density of More than 20 kW/L
journal, March 2011

Sato, Shinji; Matsui, Kohei; Zushi, Yusuke
Materials Science Forum, Vol. 679-680
DOI: 10.4028/www.scientific.net/MSF.679-680.738

Figures / Tables found in this record:

Figures/Tables have been extracted from DOE-funded journal article accepted manuscripts.

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Similar Records

Title: 30-kW All-SiC Inverter with 3D-Printed Air-Cooled Heatsinks for Plug-In and Full Electric Vehicle Applications

Abstract

Citation Formats

Figures / Tables:

Development of a board-level integrated silicon carbide MOSFET power module for high temperature application conference, May 2015

Forced-Air-Cooled 10 kW Three-Phase SiC Inverter with Output Power Density of More than 20 kW/L journal, March 2011

Development of a board-level integrated silicon carbide MOSFET power module for high temperature application
conference, May 2015

Forced-Air-Cooled 10 kW Three-Phase SiC Inverter with Output Power Density of More than 20 kW/L
journal, March 2011