Vitesco Technologies Power Module in Jaguar I-PACE

©2021 by System Plus Consulting | SPR21610 - Vitesco Technologies Power Module in Jaguar I-PACE Inverter | Sample 1

Vitesco Technologies Power Module in Jaguar I-PACE Inverter

Multiple optimized packaging innovations for this automotive power module from Vitesco Technologies.

REVERSE COSTING® – STRUCTURAL, PROCESS & COST REPORT

22 bd Benoni Goullin44200 NANTES - FRANCE +33 2 40 18 09 16 [email protected] www.systemplus.fr

SPR21610 – Power Electronics report by Amine ALLOUCHELaboratory Analysis by Léo VATANT & Youssef EL GMILI

May 2021 – Sample

http://www.systemplus.fr/


SUMMARY

Overview / Introduction 4

o Executive Summary

o Market

o Reverse Costing Methodology

o Glossary

Company Profile 9

o Vitesco Technologies Company Profile

o Vitesco Technologies Product Catalog

Physical Analysis 17

o Synthesis of the Physical Analysis

o Package Analysis

✓ Package Opening

✓ Package Cross-section

o Si IGBT Die

✓ IGBT Die View & Dimensions

✓ IGBT Die Process

✓ IGBT Die Cross-section

o Si Diode Die

✓ Diode Die View & Dimensions

✓ Diode Die Process

✓ Diode Die Cross-section

Physical Comparison 88

o Vitesco Technologies vs Infineon Power Modules

Manufacturing Process 90

o Si IGBT Fabrication Unit

o Si IGBT Process Flow

o Si Diode Fabrication Unit

o Si Diode Process Flow

o Final Test & Packaging Fabrication unit

o Packaging Process Flow

Cost Analysis 104

o Synthesis of the Cost Analysis

o Yields Explanation & Hypotheses

o Si IGBT

✓ IGBT Front-End Cost

✓ IGBT Wafer Cost per Process Step

✓ IGBT Die Probe Test & Dicing

✓ IGBT Die Cost

o Si Diode

✓ Diode Front-End Cost

✓ Diode Wafer Cost per Process Step

✓ Diode Die Probe Test & Dicing

✓ Diode Die Cost

o AMB Cost

✓ AMB BOM Cost & Assembly Cost

o Module Cost

✓ Packaging BOM & Assembly Cost

✓ Module Final Cost

Cost Comparison 125

o Vitesco Technologies vs Infineon Power Modules

Selling Price Analysis 127

o Estimation of selling price

Feedback 129

Related Analyses 131

Company Services 133



Overview / Introductiono Executive Summaryo Marketo Reverse Costing

Methodologyo Glossary

Company Profile & Supply Chain

Physical Analysis

Physical Comparison

Manufacturing Process Flow

Cost Analysis

Cost Comparison

Selling Price Analysis

Related Analyses

About System Plus

Executive Summary

The new environmental regulations to reduce average CO² emissions and automotive trends play in favor of greater vehicle electrification and faster deployment of Electric Vehicles/Hybrid Electric Vehicles (EV/HEVs). YoleDéveloppement expects that the EV/HEV market will reach 41 million vehicles by 2026.

Innovations in power module design are continuously being developed for enhanced performance. We can find them in all power module structures, from the baseplate and substrate assembly down to the die attach, through the electrical connection.

In this context, System Plus Consulting provides a full reverse costing study of the Vitesco Technologies IGBT Power Module integrated in Jaguar’s I-PACE Inverter.

First of all, the module uses an innovative chip assembly process with double side sintering. Moreover, to enhance electrical performance, clip connections and substrates are optimized for silver sintering. In addition, the baseplate is designed specifically for strict automotive performance requirements.

Supported by a full teardown of the module, this report reveals Vitesco Technologies’ choices in packaging as well as the designs of its IGBT and diode chips.

This report provides insights into technology data, manufacturing cost and selling price of the module. It includes an estimated manufacturing cost of all the module’s components and its selling price analysis.

The report also includes a comparison between the analyzed Vitesco Technologies power module with the Infineon HybridPACK™ Drive FS820R08A6P2B. These comparisons highlight differences in the packaging design and costs.



Overview / Introduction


Physical Analysis o Synthesiso Packageo Si IGBT Designo Si Diode Design

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

Package Characteristics

o Package type: Plastic Case

o Overall dimensions: xxx mm x xxx mm x xx mm

o Total mass: xxx grams

o Number of terminals: xx

o Silicone gel weight: xx grams

Package Front side – Optical View©2021 by System Plus Consulting

Plastic caseCut terminals

BaseplatePackage Tilted – Optical View

©2021 by System Plus Consulting






Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

Package Opening

Package Opening Tilted – Optical View©2021 by System Plus Consulting

Package Opening Tilted – Optical View©2021 by System Plus Consulting

xxx clip xxx attach of clip on

diode die

xxx attach of dies on AMB substrate

Diode

IGBT






Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

Si IGBT – Die Dimensions

IGBT Die – Optical View©2021 by System Plus Consulting

o Die dimensions:xxx mm² (xxx mm x xxx mm)

Xxx

mm

xxx mm






Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

Die Cross-Section – Termination






Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

Die Delayering – Optical View©2021 by System Plus Consulting

Die Process – Emitter Region Delayering

Die Delayering – SEM View©2021 by System Plus Consulting

Pitch: xxx µmDie Delayering – Optical View

©2021 by System Plus Consulting






Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

Die Cross-Section





Physical Analysis

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

Vitesco Technologies vs Infineon Automotive Power Modules – Comparison





Physical Analysis

Physical Comparison

Manufacturing Process Flowo Si IGBT Fab Unito Si IGBT Process Flowo Si Diode Fab Unito Si Diode Process Flowo Packaging Fab Unito Packaging Process Flow

Cost Analysis

Cost Comparison


Related Analyses

About System Plus

IGBT Process Flow (2/3)

Gate poly

• Gate oxide

• Polysilicon

Oxides

• Si oxide 1 patterning

• Si oxide 2/3/4/5/6 patterning

Contact

• Silicon etching (for contact opening)

• PVD xxx

Drawing not to Scale

Gate oxidePoly

Si oxide 1Si oxide

Contact openingxxx

xxx





Physical Analysis

Physical Comparison


Cost Analysiso Synthesiso Si IGBT Costo Si Diode Cost o AMB Costo Packaging Costo Module Cost

Cost Comparison


Related Analyses

About System Plus

IGBT Die Cost





Physical Analysis

Physical Comparison


Cost Analysiso Synthesiso Si IGBT Costo Si Diode Cost o AMB Costo Packaging Costo Module Cost

Cost Comparison


Related Analyses

About System Plus

AMB Cost



R E L A T E DA N A L Y S E S




Physical Analysis

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Plus

RELATED TEARDOWN TRACKSRELATED REPORTS

By System Plus Consulting:• Silicon IGBT Comparison 2021

• Hitachi Double-Side Cooling Power Module from Audi e-tron’sInverter

• StarPower GD820HTX75P6H Tri-Pack IGBT Module

By Yole Développement:• Status of the Power Module

Packaging Industry 2020

• Power Electronics for E-Mobility 2021

By System Plus Consulting:• Continental Inverter for Jaguar

i-Pace (J9D3-14G138-AJ)

Related Analyses


https://www.systemplus.fr/reverse-costing-reports/silicon-igbt-comparison-2021/

https://www.systemplus.fr/reverse-costing-reports/hitachi-double-side-cooling-power-module-from-audi-e-trons-inverter/

https://www.systemplus.fr/reverse-costing-reports/starpower-gd820htx75p6h-tri-pack-igbt-module/

https://www.i-micronews.com/products/status-of-the-power-module-packaging-industry-2020/

https://www.i-micronews.com/products/power-electronics-for-e-mobility-2021/

https://www.reverse-costing.com/teardowns/continental_inverter_for_jaguar_ipace/


COMPANYSERVICES




Physical Analysis

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses

About System Pluso Company serviceso Contact

Our Core Activity : Reverse Costing®

A Structure, Process and Cost Analysis

Reverse Costing® consists of disassembling a device or a system in orderto identify its technology and discern its manufacturing processes andthen using in-house models and tools to determine its cost.





Physical Analysis

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses


Fields Of Expertise





Physical Analysis

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses


Business Model

Teardown Track

205+ teardowns per

year

Monitor1 per year quarterly updated

Custom Analysis150 custom analyses per

year

Report60+ per year

Costing Tools

5 process-based and 3 parametric

costing tools

Cost MethodsTrainingOn demand





Physical Analysis

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses


Worldwide Presence

100+ collaborators in 8 different countries

Headquarters› Nantes – System Plus Consulting› Lyon – Yole Développement

Boise

CorneliusRaleighPhoenix

Austin

Singapore

Hsinchu

TokyoShenzhen

Seoul

Frankfurt

Nantes

Lyon





Physical Analysis

Physical Comparison


Cost Analysis

Cost Comparison


Related Analyses


Contact

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Vitesco Technologies Power Module in Jaguar I-PACE