The application of SiC on vehicles and its future

1

The application of SiC on vehicles

and its future

4th July, 2018

Dr. Kimimori Hamada

Project General Manager

EHV Electronics Design Div.

Toyota Motor Corporation

Center for Power Electronics Annual Conference 2018Loughborough University

2Contents

1. Vehicle Electrification

- Toyota’s strategy

- Development of electrified vehicles

- Vehicle electrification technologies

- Application of SiC Power Semiconductor Devices on Electrified Vehicles

2. SiC device technologies to expand automotive use

- Development of Trench MOSFET With Ultra Low RonQgd

- Stacking Fault Expansion and the Countermeasures

3. Summary









3. Summary

3What our customers and society require for cars

4To reduce CO2 emissions・・・

5Global Population Growth and Vehicle Units in Operation

Sources: 1) United Nations Department of Economic and Social Affairs2) World Business Council for Sustainable Development

10

5

0

(in billions)

1950 2000 2050 2100

Asia

Africa

North America

Europe

Un

its in

op

era

tion

(in

billion

s)

0

1

Units in operation

Population

1 vehicle per 40 people

750 mil. units

1 vehicle per 8 people

Population

Population and number of vehicles on load will grow mainly in emerging markets

70 mil.units

Latin America, Caribbean

Oceania

6

1) Improving fuel efficiency

To address 3 issues,vehicle electrification is essential

3) Making emissions cleaner to prevent air pollution

Environment-friendly vehicles contribute to the environment only when widely used.

Toyota’s Basic Response

2) Reducing CO2 to prevent global warming

7

Toyota’s development of electrified vehicles

Contents

8

FCV

Passenger cars

Route buses

Travel distance

Home deliveryvehicles

HV/PHV

Short-distance commuter vehicles

Personal mobility

Full-size trucks

Home delivery trucks

EV

EVs: Short-to-medium distance; HVs & PHVs: Wide-use; FCVs: Medium-to-long distance

Environmentally friendly electrified vehiclesV

eh

icle

siz

e

9

2020 20502010

EV

PHV

FCVEV

Challenge 1: New-vehicle Zero CO2 Emissions Challenge

2010 2050

Average CO2

emissions for new vehicles

90％ reduction

HV

Accelerate next-generation vehicle development

toward 90% reduction in CO2 emissions

New Vehicle Zero CO2 Emissions Challenge

Vehicles poweredby only internal

combustion engines

10Vehicle electrification milestones

1990 20502010 204020202000 2030

2050: Zero CO2emissions challenge

1997: World’s firstmass-production HEV

2030

Electrified vehicles > 50%

BEV･FCEV >10%

By around 2025:Electrified gradeavailable for allvehicle models

PHEVs

HEVs

FCEVs

BEVs

From 2020:BEV rolloutin earnest

2014: FCEV

Vehicles poweredby only internal

combustion engines

11

0

20

40

60

80

100

120

140

160

180

200

0

100

200

300

400

500

600

700

800

900

1,000

1,100

1997 1999 2001 2003 2005 2007 2009 2011 2013 2015 2017

販売台数

（年間）

販売台数

（累計）

累計（万台）年間（万台）

100万台

300万台

500万台

（1月）0

200

400

600

800

1,000

1,200

1,400

1,600

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

CO2削減量

（年間）

CO2削減量

（累計）

累計（万t）年間（万t）

0

100

200

300

400

500

600

700

800

900

1,000

1,100

1997 1999 2001 2003 2005 2007 2009 2011 2013 2015 2017

0

200

400

600

800

1,000

1,200

1,400

1,600

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

77 mil. tons

9 mil.

0

20

40

60

80

100

120

140

160

180

200

No. of units sold (annual)

No. of units sold (total)

CO2 reduction (annual)

CO2 reduction (total)

0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0 Yearly(in millions of units)

0

2

4

6

8

10

12

14

16

Yearly(in millions of tons)

10 million

Toyota HV Sales Results & CO2 Reduction

5 mil.

3 mil.

1 mil.

Total HV sales reached 10 million units in January 2017!CO2 reduction compared to similar gasoline-engine vehicles was 77 mil. tons.

11

10

9

8

7

6

5

4

3

2

1

0

0

10

20

30

40

50

60

70

80

Total(in millions of units)

Total(in millions of tons)

Total sales11.09 mil., units(at end of Sept. 2017)

12

GlobalTotal

Toyota

(Unit: 1,000 vehicles)Calculated by Toyota from IHS data

HV2,410

HV+PHV+FCV1,400

EV490

PHV330

FCV2.6

43%Electrified VehicleMarket Share (CY 2016)

3,232

Top OEM of Electrified Vehicles

13

Toyota’s vehicle electrification technologies

Contents

14

Motor

Battery

PCU(Inverter)

Charging

EV

Engine Charging

PHV

Engine

HV

Fuel Cell HydrogenTank

FCVH2

O2

H2

3 Core Technologies and Electrified Vehicles

15

Motor

PCU

Battery

Output：200%

Volume：50%

Weight：30～50%

Energy loss：80%

Volume：60%

Volume：50%

UP DOWN

DOWN

DOWN

DOWN

DOWN

Power Density400%

UP

Evolution of 3 Core Technologies

16

燃費（km/L）

HVシステムコスト

10-15 Japanese test cycle

JC08 Japanese test cycle

HV system cost

Fuel efficiency (km/L)

First-generation PriusSecond-generation Prius Third-generation Prius New Prius

HV technology significantly evolved in fuel efficiency with reduced

cost

燃費（km/L）

HVシステムコスト

10-15 Japanese test cycle

JC08 Japanese test cycle

HV system cost

Fuel efficiency (km/L)

1st-generation Prius 2nd-generation Prius 3rd-generation Prius New Prius

HV technology significantly evolved in terms of fuel efficiency

with reduced cost

Higher Fuel Efficiency & Lower Hybrid System Costs

17

Application of SiC Power Semiconductor Devices on Electrified Vehicles

Contents

18CAMRY

Full SiC PCU

SiC MOSFET SiC JBS Diode

・Installing SiC power semiconductors (MOSs and diodes) in the PCU・We started road testing of this Camry in early February, 2015・Evaluating fuel efficiency under various driving condition

19Fuel cell system of the FC bus

FC Boost Converter FC Stack

FC boostConverterSiC JBS Diode

20Tokyo Toei FC Bus

・Regular commercial operation in Tokyo since March, 2017

・Over 100 FC Buses will be introduced before Tokyo Olympic/Paralympic games

To(都)05line: Tokyo station Marunouchi-Minamiguchi～Tokyo Big Sight

21

Toyota Drives the Future of Zero Emission Trucking

The Project Portal heavy-duty truck concept generates more than 670 horsepower and 1,325 pound

feet of torque from two Mirai fuel cell stacks, and its estimated driving range is more than 200 miles

Heavy-duty FC Track

22

Toyota Promotes CO2 Emission Reduction and Energy Conservation in Convenience Store Distribution and Operation

Next generation Convenience Stores and Small FC Truck

https://newsroom.toyota.co.jp/en/corporate/22833613.html?padid=ag478_from_kv

23

Toyota Strongly Promotes the Development of Electric Vehicles.

Toyota to Introduce 10 New Electrified Vehicles

in China by 2020

Electric Vehicles

City Commuters

E-Palette Concept

24Contents









3. Summary









3. Summary

25

ICSCRM2007(Ohtsu) Keynote Speech

Challenges to reduce cost:

1) Development of Low RonQgd MOSFET 2) Practical use of body diode of MOSFET

26

Development of Trench MOSFET With Ultra Low RonQgd

Deep-P Encapsulated 4H-SiC Trench MOSFETs With Ultra Low RonQgd

(DENSO@ISPSD2018)

Contents

27Development of ultra low RonQgd power MOSFET

[1] DENSO REVOSIC HP https://www.denso.com/jp/ja/products-and-services/industrial-products/sic/





32

Stacking Fault Expansion due to Body Diode Operation and the Countermeasures

Contents

33

Gate

Source

Drain

Vg：OFF

H

L

0

Vdd

VRon

Vf

Time chart of synchronous rectifier operation

Vg

Idiode

Vak

Synchronous Rectification

Vg：ON

Synchronous

P

N

Dead TimeDead Time

0

rectification

・In order to reduce conduction losses and device cost,the synchronous rectification is important technology.

・However, the body diode of MOSFET operates during dead time.

34Types of Stacking Faults

・There are Two types of Stacking Faults: Triangle and Bar-shaped.・The expansion of the triangle SFs ended when the shape reached a triangle.・Bar-shaped SFs expand continuously to the end of the active area.⇒ Larger impact on electrical properties.

11-20

35

-6.00

-8.30 -8.55 -8.59-10.0

-8.0

-6.0

-4.0

0.0 10.0 20.0 30.0

VD

S(V

)

Stress Time (min)

VF(Ids=200)

6.809.59

16.04

16.63 16.79

5.0

10.0

15.0

20.0

0.0 10.0 20.0 30.0

VD

S(V

)

Stress Time (min)

VON(Ids=200)

1minInitial 2min 3min 5min 7min 10min 20min 30min

11-20

Stacking Faults Expansion

36

Y. Ebiike, et. al., Mitsubishi Electric Corporation, ISPSD (2018)

Effect of Thickness of Buffer layer to suppress the expansion of SFs

3.3 kV 4H-SiC MOSFETs with various buffer layer thickness has been fabricated in order to investigate the bipolar degradation associated with the expansion of stacking faults.

“Reliability Investigation with Accelerated Body Diode Current Stress for 3.3kV 4H-SiC MOSFETs with Various Buffer Epilayer Thickness”

37

K. Kawahara, et. al., Mitsubishi Electric Corporation, ISPSD (2017)

The purpose of this work is to remove external SBD chips from modules while maintaining device reliability to realize compact high Voltage SiC modules that are free from bipolar degradation.”

Embedded SBDs in planar SiC MOSFETs

“6.5 kV Schottky-Barrier-Diode-Embedded SiC-MOSFET for Compact Full-Unipolar Module”

38

Y. Kobayashi, et. al., Fuji Electric Co. Ltd. and AIST, IEDM (2017)

SWITCH-MOS (SBD-wall integrated trench MOSFET)

"Body-PiN-diode inactivation with low on-resistance achieved by a 1.2 kV-class 4H-SiC SWITCH-MOS"

39SWITCH-MOS (SBD-wall integrated trench MOSFET)

Y. Kobayashi, et. al., Fuji Electric Co. Ltd. and AIST, IEDM (2017)

40Contents









3. Summary









3. Summary

41Summery

1. Automotive industry is facing profound transformation that comes only once in

100 years.

2.Toyota will strategically develop new values, “Electrification”, “Information” and

“Intelligence”.

3.Toyota believes vehicle electrification is essential to reduce CO2. We accelerate

next-generation electrified vehicles development.

4.In order to expand SiC application on vehicles to contribute toward the reduction

of CO2, we have to reduce total cost of system. Low RonA device development and

improving reliability are key activities for engineers and researches.

Documents

The application of SiC on vehicles and its future