The Fraunhofer Institute for Reliability and Microintegration (IZM), in collaboration with Bosch and Porsche, has developed a power inverter specifically tailored to the demands of high-performance electric vehicles. Under the project name “Dauerpower,” the inverter achieves peak outputs of up to 720 kilowatts and combines silicon carbide (SiC) semiconductor technology with 3D-printed cooling components. The development objective was to ensure long-term load stability within a compact design, while minimizing energy losses.
At the core of the design is the use of SiC transistors, which offer lower on-state resistance and higher thermal tolerance compared to conventional silicon components. The module inductance was intentionally kept low at 1.1 nanohenries, enabling faster switching speeds and reducing switching losses. Combined with embedded PCB technology, this helps to suppress parasitic effects, improve thermal integration, and increase overall system efficiency.
Dominik Seidenstücker, a lead developer of the project, highlights additional advantages: “Compared to standard silicon transistors, silicon carbide semiconductors exhibit significantly higher thermal stability, lower parasitic capacitance, and reduced on-resistance for the same chip area. As a result, they offer great potential to reduce both conduction and switching losses.”
Thermal stability is ensured by a two-part cooling system based on 3D-printed copper and aluminum components. The copper heat sink distributes heat locally, while the aluminum cooling channel removes waste heat using a water-glycol mixture. “We chose copper for its superior thermal conductivity compared to aluminum, which allows better heat spreading,” explains Seidenstücker.
Seidenstücker further notes: “Embedding the power modules in the PCB lets us reduce the distance between current paths, which minimizes stray inductance. Lower stray inductance allows for faster switching, which in turn reduces semiconductor losses again.”
Pressure drop in the cooling system remains low, at just 150 millibars with a flow rate of ten liters per minute, ensuring consistent power output without thermal overload.
With a power density of 200 kVA per liter, the system outperforms typical automotive series inverters. Its modular design also simplifies maintenance and part replacement. The Dauerpower inverter will be showcased from May 6 to 8 at PCIM Europe in Nuremberg. The project received funding from the German Federal Ministry for Economic Affairs and Climate Action.
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