Green Power for the Future: AT&S Revolutionizes e-mobility

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The dream of an electric car that is fully charged within ten minutes and then delivers a range of 1000 kilometers is no longer unrealistic. Modern batteries, fast charging stations and efficient semiconductor-based electronics to manage high voltages and currents have ensured that electric cars have become increasingly competitive in terms of travel comfort in recent years. However, fundamental changes to the power electronics are necessary to achieve further improvements.

“The alternating current from the grid is converted into direct current, which can be stored in the batteries, with converters. The higher the electrical power that the system can absorb, the faster I can charge an electric car. This requires power electronics that can handle high currents and voltages. Current converters use semiconductor circuits that we connect using wire bonding technology, the service life of which decreases as the required power increases. We have developed solutions that allow car manufacturers to realize the next generations of their fast charging technologies,” explains AT&S CTO Peter Griehsnig.

Lighter, tougher and greener

AT&S combines alternative semiconductor materials such as gallium nitride and silicon carbide with innovative power embedding technology to produce switches for converters that are smaller, more durable and more efficient than existing models. “Our embedded semiconductor chips can withstand up to 1500 volts and up to 200 amps. Converters with our embedding technology take up less space, save weight and are flexible in design. Many car manufacturers are already showing interest and are working with us on future developments in several EU research projects such as ‘HiEfficient’ and ‘HiPower 5.0’,” says AT&S Program Manager Mike Morianz.

Modules with semiconductors made of gallium nitride and silicon carbide are currently manufactured using wire bonding technology. With its power embedding, AT&S is able to embed several semiconductor chips in parallel using microvia technology and sinter lamination according to specified designs. “This significantly improves efficiency and reliability. Losses are lower, the solution takes up only half as much space and lasts ten times as many switching cycles as conventional technology,” Morianz explains.

Range and fast charging technologies are becoming increasingly important, and not just in electric cars. In Scandinavia, battery-powered ferries that can be charged in just a few minutes during docking times are already being tested. In such innovative scenarios, AT&S can help partners to make the traffic and transportation infrastructure of tomorrow more durable and sustainable.