Design of a High-Frequency Transformer and 1.7 kV Switching-Cells for an Integrated Power Electronics Building Block (iPEBB)

This paper presents the design of a 250 kW integrated power electronics building block (iPEBB) for future electric ship application. This work focuses on the motivation, design choices, and initial prototyping of a 500 kHz transformer and 1.7 kV SiC switching-cells which form the core of the converter. The transformer is designed for 13.8 kVAC and utilizes electric-field-grading conductive insulation layers. Furthermore, new insulating substrate technologies and layouts are explored to meet the challenges of developing a fast switching, low inductance switching-cell. Electrical, thermal, and weight analysis for the switching-cells are explored to achieve a power loop inductance of 3.5 nH and maximum junction temperature of 175 °C. The packaging of 1.7 kV SiC MOSFET switching-cells based on these substrates is also presented. This work will help advance the development of a light-weight, fast-switching iPEBB to serve as the backbone for power distribution systems on electric ships.