Mechatronic design of 2 kW SiC DC/AC converter with 200 W/inch

Google's Little Box Challenge has shown that very high power densities can be reached for DC/AC converters in the 2 kW power range with wide band gap power semiconductors. With an additional mechatronic design approach and by using a 6-switch power topology based on latest 900 V SiC MOSFETs, the Fraunhofer IISB has reached a power density of 201 W/inch(exp 3) (86.5 mm x 75.5 mm x 25 mm = 0.163 dm(exp 3) @ 2 kW). This paper presents the utilized topology as well as applied mechatronic system design of passive components, power stage and cooling devices to reduce the overall volume of the converter. Concluding measurement results of power stage and cooling system of the converter are presented and discussed.