Fraunhofer IZM, in collaboration with Porsche and Bosch, is developing an electric drive inverter for electric vehicles that offers higher performance and efficiency thanks to innovative 3D printing and cooling technologies.
The use of heat-resistant silicon carbide for transistors and copper cooling elements from 3D printers enables improved heat dissipation and a more compact design, leading to reduced power loss and material costs.
Fraunhofer IZM Advances Development of Drive Inverters in Collaboration with Porsche and Bosch.
Overheating components often significantly limit the performance of electric vehicle drive trains. In the project "Dauerpower," Fraunhofer IZM, together with project partners from the automotive industry, is developing an electric inverter that can operate at lower operating temperatures due to optimized cooling management. This reduces power loss and enables longer full-load use, thereby reducing costs for electromobility.
The development focuses on a compact 3-phase drive inverter with high continuous power of 720 kilowatts or 979 horsepower and a rated current of 900 amperes, in cooperation with Porsche and Bosch. This innovative inverter is expected to achieve a performance increase of 20% to 30% compared to conventional systems.
An important role is played by transistors made of heat-resistant silicon carbide, which have higher temperature resistance and efficiency. These are applied directly to a ceramic substrate in an innovative pre-packaging process and can be flexibly integrated into conventional circuit boards.
In addition, copper is used in a 3D printing process to manufacture cooling elements. This allows for optimal heat dissipation and a more compact arrangement of the chips, resulting in improved cooling efficiency and reduced material consumption.
