High Power Density SiC Power Module for Formula E: Requirement, Design Considerations and the Test Results

Abstract:
Power converters utilized in Formula E, due to the demanding requirements and competitive nature, require fully optimized power semiconductor modules, including the latest device and packaging technologies. In this paper, firstly, the key requirements of Formula E are presented and compared with the standard electric vehicle applications. In the next step, the design considerations such as semiconductor device selection, electromagnetic design, switching conditions and losses, cooling schemes and effect of packaging component selection on the thermal resistance, module integration and power density are discussed. Finally, the characteristics and the capabilities of the RoadPak module optimized for utilization in a Formula E power inverter are demonstrated.