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We are entering the “silicon carbide era.”

Release time:

2020-09-18

With the advent of a new computing era driven by the Internet of Things (IoT), big data, and artificial intelligence (AI), the demand for energy-efficient chips is steadily growing. In this context, we often turn to Moore’s Law, which calls for shrinking the size of transistors.

However, advances in power semiconductors do not depend solely on shrinking transistor dimensions. Silicon power switches, such as MOSFETs (metal-oxide-semiconductor field-effect transistors) and IGBTs (insulated-gate bipolar transistors), are used to handle voltages ranging from 12V to +3.3kV and currents of several hundred amperes. These switches consume a great deal of energy! Yet their capabilities are limited, which has spurred the development of new materials like silicon carbide (SiC)—materials that hold promise for delivering superior performance.

Silicon carbide is a compound semiconductor material that combines silicon and carbon, creating a “super cousin” of silicon. Compared to silicon, silicon carbide requires more than three times the energy to enable electrons to start moving freely. This wider bandgap endows the material with intriguing properties, such as faster switching speeds and higher power densities. The following sections will focus on two specific use cases that highlight the significant benefits silicon-carbide devices can offer.

SiC for automotive

According to data from the research firm Yole Development, there are more than 1 billion cars worldwide. As of 2017, 1.9 million vehicles—about 0.2%—were electric cars. By 2040, this share is expected to rise to 50%; therefore, improving power efficiency is of paramount importance.

Electric vehicles typically have a main motor that drives the wheels, and six power transistors and diodes are used to power the motor. Each transistor needs to be capable of blocking 700V and switching several hundred amperes. Most power switches employ pulse-width modulation (PWM) technology, which means they switch on and off tens of thousands of times per second. When a transistor switches from one state to another, there is a transition delay between these states (Figure 1). Just as it takes time to fully open or close a faucet—during which some water may be wasted—similarly, in power applications, a key objective is to maximize switching speed as much as possible, thereby reducing switching losses and achieving higher efficiency.

Superior switching performance, low on-state resistance, and high breakdown voltage make SiC devices an ideal replacement for conventional silicon power devices (MOSFETs), DC-DC converters, uninterruptible power supply systems, and motor applications (Figure 2).

Using SiC MOSFETs allows electric vehicles to drive their motors with lower power consumption, ultimately extending the vehicle’s driving range. Thanks to higher switching frequencies, which result in greater power density and smaller, lighter motors, reduced heat dissipation also enables electric vehicles to use smaller, lighter radiators, further optimizing vehicle weight and increasing driving range.

SiC for solar energy

Another application of SiC is in solar inverters, where its size is only half that of IGBT-based solutions. The faster switching speed of SiC enables manufacturers to reduce the size of passive components in the system. Large capacitors and transformers can be replaced with smaller alternatives, while also allowing for a reduction in the size of heat sinks. As system efficiency improves, energy harvesting is maximized.

Use SiC

Although SiC devices hold exciting and enormous potential, manufacturing challenges remain today. A major issue is substrate defects; to achieve the high yields necessary for commercial success, SiC devices must significantly reduce these defects. Applied Materials is collaborating with ecosystem participants—including SiC wafer manufacturers and IDM (integrated device manufacturers)—to specifically address manufacturability challenges. We’ll discuss further developments in this area in a subsequent update.

Many industry forecasters believe that SiC will eventually replace silicon in applications requiring higher voltages and greater power consumption. Just like all superheroes, once the industry embraces SiC, it will be able to tackle even greater challenges in power consumption and efficiency, thereby making the world a better place.

The Shandong Provincial Department of Industry and Information Technology released the list of “Hidden Champions” among small and medium-sized enterprises for 2018, and Weifang Huamei Fine Technical Ceramics Co., Ltd. was included on the list.

Weifang Huamei Fine Ceramics Co., Ltd. is delighted to have been awarded the title of “Shandong Province Demonstration Enterprise for Technological Innovation” for 2020!