Converter-Level Packaging and Optimization for a SiC-based Grid-Interface Converter Using Discrete Devices

Abdul Basit Mirza, Kushan Choksi, Austin Zhuo, Sama Salehi Vala and Fang Luo
IEEE Transactions on Components, Packaging and Manufacturing Technology, 2024
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Abstract: Grid-integration of renewables through power electronic Grid-Interface Converters (GICs) is essential for achieving a sustainable grid. This mission involves developing compact, efficient converters with standardized interfaces to minimize redundancy. In line with this objective, this paper presents an electro-mechanical-thermal design and packaging of a two-stage SiC-based 75 kVA GIC using TO-247 discrete devices with two times lower cost-to-power ratio than power modules. The power stage is 3-D packaged on a cylindrical-hole-based three-face utilized heat sink to achieve 5.5 kW/L power density, including passive components. For the DC-AC stage, Two-Level Split-Phase topology (2L-SP) is employed, owing to its lower switching loss and output dv/dt and increased cross-talk immunity compared with simple Two-Level (2L) topology. An equivalent switching transition circuit is derived for optimal sizing of split inductors in 2L-SP. Further, for device interconnection, an optimized PCB layout with flux cancellation and minimum board parasitic capacitance is developed for optimal device switching with minimum voltage overshoot. Moreover, for magnetics, split-direct winding technique is employed to achieve minimum winding capacitance. Lastly, the developed GIC is systematically tested at rated system voltage with an RL load at 10 kVA.

Recommended citation (BibTex):

@ARTICLE{MirzaIGIBC2024, author={Mirza, Abdul Basit and Choksi, Kushan and Zhou, Austin and Vala, Sama Salehi and Luo, Fang}, 
 journal={IEEE Transactions on Components, Packaging and Manufacturing Technology}, 
 title={Converter-Level Packaging and Optimization for a SiC-based Grid-Interface Converter Using Discrete Devices}, 
 year={2024}, 
 volume={}, 
 number={}, 
 pages={1-1}, 
 doi={10.1109/TCPMT.2024.3385398} 
}