high dielectric constant capacitors for power electronic ... · high dielectric constant capacitors...

High Dielectric Constant Capacitors for Power Electronic Systems*

U. (Balu) BalachandranArgonne National Laboratory

Team members at Argonne: B. Ma, M. Narayanan, and S. E. Dorris

This presentation does not contain any proprietary, confidential, or otherwise restricted information

*Work supported by the U.S. Department of Energy, Office of Vehicle Technologies Program.

Project ID# ape_05_balachandran

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -2-

Overview

• Project start date: FY04• Project end date: FY12• Project continuation & direction

determined annually by DOE• Percent complete: 60

• Overall size and cost of invertersCapacitors are a significant fraction of the inverter volume (≈35%), weight (≈23%), and cost (≈23%).

• High-temperature operationThe performance and lifetime of presently available capacitors degrade rapidly with increasing temperature (coolant temperature of 105°C).• Total project funding

– DOE share: 100%• Funding received in FY08: $940K• Funding for FY09: $800K

Timeline

Budget

Barriers addressed

• Penn State University• Delphi Electronics• Project Lead: Argonne National

Laboratory

Partners

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -3-

Objectives• Overall objective is to develop

technology for fabricating a range of new, high performance, economical, capacitors for power electronic systems in HEVs, PHEVs, and FCVs.

DC bus capacitors for inverters– (600 V, 2000 µF, <3 mΩ ESR, 250 A

ripple current,140°C, benign failure)

• Objective for FY08 was to fabricate and characterize high voltage capable dielectric films on base-metal foils (“film-on-foils”) that meet or exceed the needs of hybrid electric vehicle power inverters.

• Dielectrics films will have:– An operational temperature range of

-50°C to +140°C– 600 V DC bus capability– High k (>1000) and Eb (>3 MV/cm) to

meet weight & volume target

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -4-

Relevance to Overall DOE Objectives of Petroleum DisplacementAdvanced inverters are essential for electric traction operations in HEVs, PHEVs, and FCVs.

Future availability of advanced high-temperature (together with lower cost, weight, & volume) inverters will advance the marketplace application of highly fuel efficient & environmentally beneficial hybrid vehicles.

Capacitors have direct impact on overall size, cost, & performance of inverters.

Capacitor development will reduce the size & increase the temperature of operation of one of the largest components in the inverter: the DC bus capacitor.

This project is developing dielectric films that has potential to reduce size, weight, and cost, concomitant with increased capacitance density & high temperature operation, for capacitors in inverters in HEVs, PHEVs, and FCVs.

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -5-

Milestones2008

Q1 Q2 Q3 Q4

2009

Q1 Q2 Q3 Q4

PLZT/Ni film-on-foil dielectric development and characterization

High voltage breakdown, HALT, reliability, & benign failure study in collaboration with Penn State

Provide samples & test results/data to industrial partner and Penn State University for verification

Decision point: Either continue the two-pronged approach, i.e., PLZT/Ni and PLZT/Cu, or down-select one over the other.

Finalize processing steps: Polishing procedure, surface roughness, & defect density in the foil will be quantified. Defects in foils translate into defects in PLZT films.

PLZT/Cu film-on-foil dielectric development and characterization

Investigate graceful failure mode

Deliver samples

Deliver report

Deliver samples

Identify processing steps

Finalize processsteps

Fabricate 1” x 1” PLZT films with uniform properties

Deliver samples

Fabricate thicker PLZT

Procure components for reliability testing

Go/No-Go

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -6-

Technical Approach• Develop ferroelectric (PLZT) dielectric films on base-metal foil (“film-on-

foil”) that are either stacked on or embedded directly into the printed wire board.

• Integration of base-metal (Ni, Cu) electrodes provides a significant cost advantage over noble metal electrodes that are used in conventional multilayer capacitors.

• Ferroelectrics possess high dielectric constants, breakdown fields, and insulation resistance. With their ability to withstand high temperatures, they can tolerate high ripple currents at under-the-hood conditions.

• Stacked and/or embedded capacitors significantly reduce component footprint, improve device performance, provide greater design flexibility, achieve high degree of volumetric efficiency with less weight, and offer an economic advantage.

• Our approach focuses on fabricating films by chemical solution deposition, developing a fundamental understanding of processing effects on properties, and arriving at robust processing strategies.

Argonne’s project addresses the technology gap in an innovative manner

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -7-

Uniqueness of Project and Impact(caps embedded directly into PWB – caps are “invisible”)

Basic ElementMetal foil coated with thinfilm PLZT dielectric

– PLZT/Ni Film-on-Foil– PLZT/Cu Film-on-Foil

ComponentStack on or embed coated foils directly into printed wire circuit board for power electronics in (P)HEV

AdvantagesReduces component footprintShortens interconnect lengthsReduces parasitic inductive losses & electromagnetic interference

metal foil (bottom electrode)

top electrode

dielectric film

Film-on-foilcapacitor

PWB Embedded capacitor with

interconnections

PWB

B (bottom electrode) T (top electrode)

Reliability is improved because the number & size of interconnections are reduced.Solder joints that are most susceptible to failure are no longer needed.

≈ 30 μm

3~4 mm

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -8-

PLZT/Ni

Bias Field (kV/cm)

tan(δ)

ε r

Cap (pF)

Temperature (˚C)ε r

D-factor

Thickness ≈ 1.15 µm

Fabricated PLZT on Ni foils with k ≈1300 & DF ≈0.08 @ 25°C and ≈1800 & 0.06 @ 150°C; mean breakdown strength >6.0 MV/cm.

(measurements made on 250-500 μm top electrodes)

Accomplishments/Progress/Results

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -9-

Accomplishments/Progress/Results (Cont.)Breakdown strength of PLZT on Ni foil – Weibull analysis

Test condition:

voltage: 200~1000V

step time: 0.5 sec

zero time: 1 sec

Film thickness: 1.15 μm

Electrode diameter: 250 μm

t

V

Higher Eb increases capacitance density and reduces dielectric layer thickness & cost of the capacitors for inverter applications.

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -10-

-150

-100

-50

0

50

100

150

-5000 0 5000

P (μ

C/c

m2 )

E (kV/cm)

Energy density ≈170 J/cm3 was measured at 1000 V.

40

60

80

100

120

140

0 1000 2000 3000 4000 5000

P (μ

C/c

m2 )

Field E (kV/cm)

Area = 168,420 mJ/cm 3

Accomplishments/Progress/Results (Cont.)Polarization & Energy Density Measured on PLZT/Ni Foil

Film thickness ≈2.0 μmApplied voltage = ±1000 V Dielectric constant ≈ 1100 at zero-bias &

115 at 300 V; 65 at 1000 VEnergy density = 168.4 J/cm3

Electrode diameter = 250 μm

0

200

400

600

800

1000

1200

1400

1600

-5000 0 5000

Calculated from PE loopMeasured with HP4192A

Ral

ativ

e Pe

rmitt

ivity

E (kV/cm)

K =115 at 300V

K = 65 at 1000V

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -11-

High-temperature measurement to predict capacitor life-time(preliminary measurement on ≈1.15 μm PLZT/Ni using 250 μm Pt electrode)

Accomplishments/Progress/Results (Cont.)

• Lifetime estimated by measuring time to failure vs. applied voltage as function of temperature.

• Mean time-to-failure (MTF), voltage acceleration factor (N), and activation energy (Ea) are obtained from reliability measurement.

-5

-4

-3

-2

-1

0

1

2

3

10 100 1000 104 105

100V120V150V

Wei

bull

Para

met

er, l

n(ln

(1/(1

-p))

tB (sec)

@ 100°C

102

103

104

105

106

107

108

20 40 60 80 100 300

0.1

1

10

102

103

104

0.2 0.4 0.6 0.8 1

Mea

n Ti

me

to F

ail (

sec)

Applied Voltage (V)

Mea

n Ti

me

to F

ail (

hr)

Applied Field (MV/cm)

N = ‐6.3@ 100°C

-5

-4

-3

-2

-1

0

1

2

3

1 10 100 1000 104

100ºC150ºC

Wei

bull

Para

met

er, l

n(ln

(1/(1

-p))

tB (sec)

@ 150 V bias

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -12-

Breakdown Strength of PLZT film on Ni foil

Test condition:

applied voltage: 200~1000V

step time: 0.5 sec

zero time: 1 sec

Film thickness: 1.15 μm

Electrode diameter: 250 μm

t

V

0

2

4

6

8

10

12

2.3 2.8 3.3 3.8 4.3 4.8 5.3 5.8 6.3 6.8 7.3 7.8 8.3 8.8

2 23

0 01

0 0 0

2 21 1

11

Cou

nts

Breakdown Strength (MV/cm)

Breakdown Strength of PLZT (8/52/48)film on LNO/Ni (25 measurements)

Cap. with large defect Cap. with small defects

Our results show that it is possible to fabricate PLZT film-on-foil dielectric films with Eb >10 MV/cm.

• Controlling the defects through process optimization will yield PLZT films with very high breakdown field (Eb).

• Higher Eb will reduce dielectric layer thickness & cost of the caps for power inverter applications.

Accomplishments/Progress/Results (Cont.)

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -13-

PLZT/Cu

Dielectric constant increased from ≈1100 to ≈1400 and loss factor decreased from 0.07 to 0.05 when temperature was increased from 25°C to 150°C.

Accomplishments/Progress/Results (Cont.)

0

200

400

600

800

1000

1200

0

0.1

0.2

0.3

0.4

0.5

-40 -30 -20 -10 0 10 20 30 40

ε r

Loss (tan δ)

Applied Field (kV/cm)

t ≈ 1µmEB ≈ 2.5 MV/cm

0

200

400

600

800

1000

1200

1400

1600

0

0.05

0.1

0.15

0.2

0.25

0.3

0 50 100 150 200

ε r

Loss (tan δ)

Temperature (°C)

-30

-20

-10

0

10

20

30

-50 0 50 100 150 200 250

TCC

(ΔC

/CR

T, %)

Temperature (°C)

X8R

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -14-

Future Work• Optimize processing conditions to make 1” x 1” size capacitors

with uniform properties (minimize defects).– substrate polishing, drying of individual layers, pyrolysis and

crystallization temperatures, & room environment influence the properties of PLZT films.

– defects in the substrates translate into defects in the dielectric layers.

• Fabricate thicker films for high-voltage applications (600 V rating, up to 700 V transient in inverters).

• Characterize the dielectric properties as function of bias voltage and temperature, and reliability of film-on-foil dielectrics.

• Investigate benign failure in multilayer architecture (demonstrated benign failure mode in single layer film-on-foil dielectrics).

• Produce prototype film-on-foils for power inverters.

2009 DOE Vehicle Technologies and Hydrogen Program Annual Merit Review & Peer Evaluation Meeting -15-

Summary

• Demonstrated dielectric films with k >1200, Eb ≈6.5 MV/cm, and Ileakage <10-8 A/cm2.

• Dielectric constant increased and loss factor slightly decreased when temperature increased from 25°C to 150°C, both causing ESR to decrease.

• Showed potential for film-on-foils with Eb >10 MV/cm; high Eb increases capacitance density and reduces amount and cost of capacitors in inverters.

• Measured energy density ≈170 J/cm3 in a ≈2 μm-thick PLZT film-on-foil.

• Demonstrated graceful failure by self-clearing method in single layer dielectric films.

• Film-on-foil dielectrics were thermally cycled (≈1000 cycles) between -50°C and +150°C with no measurable degradation in k.

• Thin ceramic dielectric on relatively thick Ni substrate is quite strain tolerant.

• A CRADA with Delphi was established to further develop and commercialize this technology.

• Over 30 publications and presentations have been made.

Developing dielectric films that has potential to reduce size, weight, and cost, concomitant with increased capacitance density & high temperature operation, for capacitors in inverters in electric vehicles.