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KEMET Webinar - What’s a Ceramic DC-LINK Capacitor Doing in My Power Converter?
- 1. What’s a Ceramic KC-LINK Capacitor Doing in My Power Converter? Webinar October 22nd, 2018
- 2. Outline 1. Power Conversion 2. Wide Bandgap Semiconductor Technology 3. KC-LINK: Overview, Performance, Competition, Ordering 4. Future Developments 5. Summary
- 3. Power Conversion Phone charger Electric vehicles Power conversion involves converting one type of electrical power to another. Solar panels
- 4. 4© KEMET Electronics. All Rights Reserved. Power Converters Basic topologies, AC-AC AC DC DC AC Input Power Output Power AC-AC 1
- 5. 5© KEMET Electronics. All Rights Reserved. Power Converters Basic topologies, DC-AC Input Power Output Power DC-AC 2 AC DC
- 6. 6© KEMET Electronics. All Rights Reserved. Power Converters Basic topologies, AC-DC AC-DC 3 AC DC DC DC Input Power Output Power
- 7. Power Converters Transistors Make it Possible! Transistors (Electronic Switch) Traditionally Silicon Based (Si)
- 8. Power Converters 3 Design Goals WeightSize Efficiency Input Output 1 2 3
- 9. Power Converters Efficiency Explained Input Power Output Power 100kW 100kW Input Power Output Power 100kW 90kW Actual Power Converter Ideal Power Converter Efficiency=100% Efficiency=90% 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑜𝑤𝑒𝑟 𝐼𝑛𝑝𝑢𝑡 𝑃𝑜𝑤𝑒𝑟 x 100%
- 10. Power Converters Solar Energy Electric Vehicles Data Centers 90% to 90.5% (+0.5%) = BIG SAVINGS Every 0.5% Matters!
- 11. 12© KEMET Electronics. All Rights Reserved. Power Converters Improving Size, Weight, and Efficiency Increase Allowable Transistor Temperature Increase Frequency Increase Voltage No bulky cooling Smaller passive components Lower losses Lower losses Reduced Weight Smaller Size Improved Efficiency 1 2 3
- 12. Power Converters Limitations with Si Based Power Converters Limited to lower temperatures Bulky cooling Limited to lower frequencies Bulky passive components Limited to lower voltages Increased losses, Larger Transistors Limitation Design Impact What about Wide Bandgap?
- 13. Wide Bandgap (WBG) Semiconductors Density of StatesElectronEnergy Non-Conductive band Semiconductor Material Bandgap Energy (eV) Germanium (Ge) 0.7 Silicon (Si) 1.1 Silicon Carbide (SiC) 3.3 Gallium Nitride (GaN) 3.4 WBG ConductorsInsulators Semiconductors 10-20 10810410010-410-810-1210-16 Conductivity (S/cm)
- 14. Frequency (Hz) Power(W) 100 1k 10k 100k 1M 10M 100M 1G 10G 100G 10 100 1k 10k 100k 1M 10M 100M The BIG 3 for WBG -Higher Voltages -Higher Frequencies -Higher Temperatures Si SiC Si Power Converter GaN Wide Bandgap (WBG) Semiconductors
- 15. Wide Bandgap Based Power Converters Smaller (Higher Power Densities) Less Cooling More EfficientPower Conversion Si Based WBG Based on GaN or SiC DC to DC 85% 95% AC to DC 85% 90% DC to AC 96% 99% Source: Mouser Electronics, L. Culberson, 2016 Typical Si 50kW inverter WBG SiC 50kW inverter
- 16. 17© KEMET Electronics. All Rights Reserved. Wide Bandgap Trend Impact on Capacitors Snubber DC Link Resonant Key Capacitor Applications
- 17. 18© KEMET Electronics. All Rights Reserved. 0.00 0.01 0.10 1.00 10.00 10 100 1,000 10,000 Capacitance(uF) Frequency kHz DC-LINK Capacitance vs Switching Frequency and Voltage 10kW Power Converter 400V 650V 1000V Wide Bandgap Trend Impact on Capacitors * Source: Prof. R. Kennel, Technical University Munich, Germany Higher Voltage = Lower Capacitance With WBG adoption, Ceramic Caps play a key role supporting semiconductors for improving efficiency in power conversion.
- 18. Wide Bandgap Trend Impact on Capacitors Capacitor RequirementThe BIG 3 for WBG Smaller, low ESR, low ESL low loss capacitors with high current handling capability Higher Switching Frequencies 20kHz → 100kHz → 100’s MHz Higher Operation Voltages 400V → 900V →1200V→1700V Reliable performance at higher voltages High Junction Temperatures 105oC → 125oC → 200oC+ Reliable performance at elevated temperatures ≥ 125oC with robust mechanical performance Packaging close to the hot semiconductor to: • Lower ESL • Minimize cooling costs
- 19. KC-LINK • AEC-Q200 automotive qualified • Very high ripple current capability • Extremely low ESR • Extremely low ESL • Operating temperature range of −55°C to +150°C • High frequency operation (>10 MHz) • No capacitance shift with voltage • No piezoelectric noise • High thermal stability • RoHS Pb-free • Wide bandgap (WBG), silicon carbide (SiC) and gallium nitride (GaN) systems • EV/HEV (drive systems, charging) • Wireless charging • Photovoltaic systems • Power converters • Inverters • LLC resonant converters • DC-Link • Snubber Features and Benefits Applications
- 20. Competition KEMET KC-LINK TDK CeraLink
- 21. Tale of the Tape KEMET KC-LINK TDK CeraLink 220nF Capacitance ~600nF CaZrO3 Dielectric Cu PLZT Yes Pb-Free No Yes RoHS Yes, only by exemption 150oC Operating Temp 150oC < 0.10% DF (%) @1kHz < 2.0% <4mΩ Typical ESR @100kHz ~65mΩ 17.1 Arms Ripple Current @100kHz, 105oC 9.7 Arms ~1nH Typical ESL ~2.5nH No, not required Lead Frame Yes, required >250 Average MOR (MPa) <125
- 22. 26© KEMET Electronics. All Rights Reserved. KC-LINK vs TDK CeraLink Capacitance Stability * Source: TDK CeraLink Datasheet KEMET KC-LINK TDK CeraLink KEMET’S KC-LINK remains ultra stable over voltage and temperature!
- 23. 27© KEMET Electronics. All Rights Reserved. 0 5 10 15 20 25 30 35 0 5 10 15 20 TemperatureRise(°C) Ripple Current (ARMS) Frequency (100kHz) KC-Link CeraLink KC-LINK vs TDK CeraLink Impedance, ESR, and Ripple Current 1.0E-04 1.0E-03 1.0E-02 1.0E-01 1.0E+00 1.0E+01 1.0E+02 10 100 1,000 10,000 100,000 Impedance&ESR(Ω) Frequency (kHz) KC-Link Impedance KC-Link ESR CeraLink Impedance CeraLink ESR KEMET’S KC-LINK ESR is lower, providing excellent ripple current handling. KC-LINK’s temperature rise remains very low (20°C) at higher ripple currents.
- 24. 28© KEMET Electronics. All Rights Reserved. KC-LINK vs TDK CeraLink Accelerated Life Testing 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% CummulativeFailures(%) Time (hours) KC-LINK CeraLink 0 250 500 750 1000 Accelerated Life Testing @600Vdc 200oC KEMET’S KC-LINK had no failures during the entire test!
- 25. KC-LINK: How to Order Commercial & Auto grade available
- 26. KC-LINK Under Development Offering Available to order now: CKC33C224KCGACTU Rest of the waterfall: UD
- 27. KC-LINK with KONNEKT Technology Under Development Voltage KC-LINK 150°C Case size 3640 Chips 4 500V 0.88uF 650V 0.60uF 1000V 220nF 1200V 190nF 1700V 88nF Uses innovative Transient Liquid Phase Sintering –TLPS– technology to bond component terminations together Cross section of KONNEKT ceramic capacitor Standard mounting Low-loss mounting
- 28. Summary • Wide Band Gap – Remember the BIG 3! • Higher Voltages • Higher Frequencies • Higher Temperatures • KEMET KC-LINK • Extremely low equivalent series resistance (ESR) • Extremely low equivalent series inductance (ESL) • Very high ripple current capability • Ideal solution for snubber, DC-LINK and resonant applications Snubber DC Link Resonant
- 29. Thank you! Ana Ogui Magaña Technical Product Specialist - Ceramic Business Unit KEMET Electronics Office Phone: +1-864-963-4580 [email protected]