Periodic Reporting for period 3 - Power2Power (The next-generation silicon-based power solutions in mobility, industry and grid for sustainable decarbonisation in the next decade.)
Reporting period: 2021-06-01 to 2022-09-30
The ECS industry is constantly moving, motivated by a knowledge driven global challenge, dealing with exceptionally complex systems but also complex components and manufacturing processes. The objectives in Power2Power aim to foster a holistic, digitized pilot line approach by accelerating the transition of ideas to innovations in the Power Electronic Components and Systems domain. In the course of this project, the international leadership of the European industry in this segment will be strengthened by means of a digitized pilot line approach along the supply chain located entirely in Europe; working together with multiple organizations, combining different disciplines and knowledge areas in the heterogeneous power-ECS environment. Only these comprehensive efforts will allow to reach a high-volume production of smart power electronics to change the market towards energy-efficient applications to meet the carbon dioxide reduction goals of the European Union (European Commission, 2018). Consequently, economic growth and tackling grand societal challenges “Energy” and “Mobility” lead to safeguarding meaningful jobs for European citizens.
Energy generation, energy conversion and smart actors are application domains where advanced high-voltage power semiconductor components primarily impact the path toward winning innovations. Advanced high voltage power semiconductor components are used wherever electrical power is generated, transmitted or used by the consumers and industry.
Silicon-based power solutions are well known since decades, however, the demand for highest energy efficiencies are growing. Based on new materials, like GaN and SiC, highest efficiencies have been shown recently, and production of those devices has started and will grow. However, Silicon-based power solutions will outperform new materials (SiC, GaN) for many more years in terms of cost-to-performance-ratio and reliability. Thus, the Silicon-based power solutions will keep innovating and growing the upcoming years.
Power2Power planned to enable innovations and create opportunities from possible disruptions by providing cost-effective high-power electronics components.
Throughout the project, the 43 partners from industry and research jointly developed novel power semiconductors with higher power density and energy efficiency. The project achieved significantly improved power semiconductor solutions for high voltages. These silicon-based IGBT solutions are also characterized by reliability and robustness, which are especially important in transport and (heavy) industrial applications, for example in battery systems and chargers for electric vehicles and high-speed drives, in power supply solutions for welding technology and for renewable energy storage in the grid. In the area of electro-mobility in particular, solutions developed by the Power2Power consortium enable a significant reduction in energy consumption and energy conversion. Through their joint efforts, the partners were able to develop novel solutions to strengthen the competitiveness of the European Power Electronics Industry.
Energy generation, energy conversion and smart actors are application domains where advanced high-voltage power semiconductor components primarily impact the path toward winning innovations. Advanced high voltage power semiconductor components are used wherever electrical power is generated, transmitted or used by the consumers and industry.
Silicon-based power solutions are well known since decades, however, the demand for highest energy efficiencies are growing. Based on new materials, like GaN and SiC, highest efficiencies have been shown recently, and production of those devices has started and will grow. However, Silicon-based power solutions will outperform new materials (SiC, GaN) for many more years in terms of cost-to-performance-ratio and reliability. Thus, the Silicon-based power solutions will keep innovating and growing the upcoming years.
Power2Power planned to enable innovations and create opportunities from possible disruptions by providing cost-effective high-power electronics components.
Throughout the project, the 43 partners from industry and research jointly developed novel power semiconductors with higher power density and energy efficiency. The project achieved significantly improved power semiconductor solutions for high voltages. These silicon-based IGBT solutions are also characterized by reliability and robustness, which are especially important in transport and (heavy) industrial applications, for example in battery systems and chargers for electric vehicles and high-speed drives, in power supply solutions for welding technology and for renewable energy storage in the grid. In the area of electro-mobility in particular, solutions developed by the Power2Power consortium enable a significant reduction in energy consumption and energy conversion. Through their joint efforts, the partners were able to develop novel solutions to strengthen the competitiveness of the European Power Electronics Industry.
Power2Power was structured to represent the value chain of power semiconductors all over Europe. The novel technologies and processes, as well as services with improved quality, efficiency and reliability that were achieved will allow the broadening of existing or the establishment of new markets. Furthermore, a stable European supply chain from raw wafers to packaging and systems was demonstrated through a pilot line approach.
A key aspect of Power2Power were innovative Si-based power semiconductor devices. The activities in work package 1 (WP1) built the basis for the advanced IGBT technologies ≥1700 V. An advanced micro-pattern trench (MPT) IGBT outperforming the current approaches was developed and a European Open Access Foundry service offers integrated isolation technology as a result of the Power2Power project.
The partners in WP5 aimed for demonstrating the broad applicability of silicon-based high-voltage and high-power IGBTs in the wide power electronics application areas of automotive, industrial applications, traction and especially the integration of renewables and grid. This also required the investigation of multiple novel or enhanced semiconductor manufacturing processes for IGBTs, related e.g. to ion implantation, metallization, device & yield optimization or contamination prevention, which was the focus of WP2. Along the value chain multiple novel or enhanced manufacturing processes, e.g. pressure-less chip soldering, wire bonding, clip sintering and automated packaging were developed, as addressed in WP3.
Additionally, in WP4, expertise on industrial workplaces which are supported by augmented reality (AR), including new knowledge from assembly to maintenance procedures, was implemented into pilot lines.
Furthermore, in work package 6, partners addressed robustness and reliability of the silicon-IGBT-based power electronics as a key differentiator for future European products. This comprised research on the device physics up to robustness on system level integration. New service segments for power module failure analysis and material testing with respect to ageing effects in power modules were also introduced.
Throughout Power2Power, the partners in Power2Power ensured the effective dissemination of the project’s results to a wide audience by various means. The projects web presence at power2power.eu presents detailed information on the project’s and individual partners’ objectives as well as project publications and key results.
Power2Power’s approach of innovation through collaboration allowed to uplift Europe’s innovation capacity and competitiveness via cooperation between European universities, R&D centers, large enterprises and SMEs. Novel products with reduced time-to-market via increased digitalization in manufacturing through pilot line approaches were demonstrated.
The first results of the Power2Power project found their way into further industrialization and usage by the potential customer. The pilot lines are ready for expansion to handle the upcoming needs of power semiconductor devices for European independence in the area of energy.
A key aspect of Power2Power were innovative Si-based power semiconductor devices. The activities in work package 1 (WP1) built the basis for the advanced IGBT technologies ≥1700 V. An advanced micro-pattern trench (MPT) IGBT outperforming the current approaches was developed and a European Open Access Foundry service offers integrated isolation technology as a result of the Power2Power project.
The partners in WP5 aimed for demonstrating the broad applicability of silicon-based high-voltage and high-power IGBTs in the wide power electronics application areas of automotive, industrial applications, traction and especially the integration of renewables and grid. This also required the investigation of multiple novel or enhanced semiconductor manufacturing processes for IGBTs, related e.g. to ion implantation, metallization, device & yield optimization or contamination prevention, which was the focus of WP2. Along the value chain multiple novel or enhanced manufacturing processes, e.g. pressure-less chip soldering, wire bonding, clip sintering and automated packaging were developed, as addressed in WP3.
Additionally, in WP4, expertise on industrial workplaces which are supported by augmented reality (AR), including new knowledge from assembly to maintenance procedures, was implemented into pilot lines.
Furthermore, in work package 6, partners addressed robustness and reliability of the silicon-IGBT-based power electronics as a key differentiator for future European products. This comprised research on the device physics up to robustness on system level integration. New service segments for power module failure analysis and material testing with respect to ageing effects in power modules were also introduced.
Throughout Power2Power, the partners in Power2Power ensured the effective dissemination of the project’s results to a wide audience by various means. The projects web presence at power2power.eu presents detailed information on the project’s and individual partners’ objectives as well as project publications and key results.
Power2Power’s approach of innovation through collaboration allowed to uplift Europe’s innovation capacity and competitiveness via cooperation between European universities, R&D centers, large enterprises and SMEs. Novel products with reduced time-to-market via increased digitalization in manufacturing through pilot line approaches were demonstrated.
The first results of the Power2Power project found their way into further industrialization and usage by the potential customer. The pilot lines are ready for expansion to handle the upcoming needs of power semiconductor devices for European independence in the area of energy.
Power2Power achieved to provide significantly improved high-voltage power solutions to substantially save CO2 emissions by successfully demonstrating reliability and robustness needed in the application domains of mobility, industry and grid. Focus KPIs achieved were reduced energy consumption, reduced cost, e.g. of rolling stock energy chargers or lifetime improvement, e.g. of electric vehicle chargers.
Power electronics systems and therefore power semiconductors are essential components in almost all sources of renewable energy. Thus, efficient power semiconductors for high power electronics “made in Europe” are of strategic importance to tackle grand societal challenges, such as the need for energy efficiency in mobility and heavy industry, distribution of electrical energy, demand for enhanced reliability and robustness. The comprehensive efforts of Power2Power make it possible to produce smart power electronics in order to steer the market towards energy-efficient applications. This is an important contribution to meeting the European Union's carbon dioxide reduction goals.
Power electronics systems and therefore power semiconductors are essential components in almost all sources of renewable energy. Thus, efficient power semiconductors for high power electronics “made in Europe” are of strategic importance to tackle grand societal challenges, such as the need for energy efficiency in mobility and heavy industry, distribution of electrical energy, demand for enhanced reliability and robustness. The comprehensive efforts of Power2Power make it possible to produce smart power electronics in order to steer the market towards energy-efficient applications. This is an important contribution to meeting the European Union's carbon dioxide reduction goals.