SBIR-STTR Award

In the Phase I effort of this this work, we will commence the development of a power conversion modular platform for very high temperature (500C) and high-level radiation environments. We will design, simulate and fabricate key components of this configurable platform. We will also prototype a specific implementation of this power conversion platform as an example application for near term space missions. The platform is based on the nascent wide bandgap semiconductor Silicon Carbide that can operate at temperatures far greater than the capabilities of silicon-based electronics. Silicon is typically rated to 220C maximum, whereas CoolCAD has fabricated MOS SiC transistors and circuits that operate above 500C, which will be utilized in this new modular platform. To realize this power conversion platform, we will design and fabricate SiC Power Transistor converter topologies, consisting of half-bridges and full bridges, as well as control electronics, into easy-to-use modular components. Multiple high temperature SiC power switching transistors (LDMOSFETs) will be integrated onto a single chip to form an easy-to-use power block. SiC high temperature CMOS control electronics that regulate the output DC distribution bus voltage while being able to supply the load current demand, will be integrated into a control component. These two modules will be relatively easy to couple together to form a complete modular power platform. Finally, in a subsequent effort, we plan to integrate the control and power electronics onto a single die that can operate at high temperature. Of course, under certain circumstances, power levels will not allow for integration into the space of a single die. Under these circumstances, the various power converter modules will be connected on a high temperature printed circuit board (PCB). The modularity and integration of SiC components will significantly streamline NASA’s power converter development efforts for future space missions. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Harsh environment SiC power converters have wide applications in (a) spacecraft power management, (b) DC distribution systems in Venus/Mercury/Mars exploration, (c) motor drives, inverters and power supply derivatives in the Space Station, satellite power systems, and (d) motor drives in 'more electric' technology applied to aircraft generators and reusable launch vehicles. SiC technology find unique applications in harsh environment CMOS-based control, driver integrated circuits and sensors, where regular Si technology cannot operate. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): Applications of high temperature (500C) harsh environment SiC power electronics include, (a) automotive engine control, (b) power management systems in ground/naval/air vehicles (c) electrical actuator and motors drives in jet engines, (d) compressors in geothermal energy, (e) deep-well drilling telemetry modules and electric actuation in gas turbines, (f) smart high-temperature sensors. Duration: 6

In this work we will develop and prototype a SiC integrated power conversion modular platform for electronics that can operate at very high temperature (500C). The platform is for NASA to use in its space vehicles and rovers to provide power to a set a different instruments and actuators from a single main DC bus line and convert it to the various other DC levels that are required by the different instruments in the vehicle. In addition, the DC-DC power converter platform will be built so that its constituent electronics are able to operate at temperature up to 500C. To enable such high temperature operation, instead of using standard silicon, which fails at approximately 250C, we are using the nascent wide bandgap semiconductor silicon-carbide (SiC) technology. CoolCAD Electronics has developed and patented fabrication methods for SiC that are enabling the construction of electronics that can operate at these high temperatures. In addition, in collaboration with the Power Electronics Group at Arizona State University, we are building entire DC-DC converter systems that can of function in these extreme environments. This requires not only building the high temperature chips and transistors, but we are also building the printed circuit boards with appropriate chip packaging, as well as novel inductors and capacitors that can reliably withstand these temperatures. In addition, we are designing the electronic circuits to be modular and scalable so that the components can be cost effectively used in a variety of applications by paralleling individual power half-bridges as well as complete half bridge modules. Finally, special circuit topologies are being developed that will allow for use of inductive and capacitive components that are realizable for very high temperature operation. In Phase 1, we developed some of these high temperature capabilities; in Phase 2, we will extend this work to develop a complete high temperature DC-DC modular power converter system. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Harsh environment SiC power converters have wide cost-effective applications in (a) spacecraft power management, (b) DC distribution systems in Venus/Mercury/Mars exploration, (c) motor drives, inverters and power supply derivatives in the Space Station, satellite power systems, and (d) motor drives in 'more electric' technology applied to spacecraft and space vehicles. SiC technology finds applications in harsh environments for SiC based control and driver integrated circuits and sensors, where regular Si technology cannot operate. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): Applications of high temperature (500C) harsh environment SiC power electronics include: (a) automotive engine control and exhaust monitoring (b) power management systems in ground and aerospace vehicles (c) electrical actuator and motors drives in jet engines, (d) geothermal energy monitoring, (e) smart high-temperature sensors, (f) controls for furnaces, gas turbines and nuclear power plants. Duration: 24