PEBB
Power Electronics Building Blocks
|
 |
Objective:
The objective of this program is to develop manufacturing
technologies for Metallized Matrix Composite (MMC) baseplates,
which will be used in Power Electronic Building Blocks (PEBBs)
to provide highly-reliable and affordable packages for modular
high power converters. Conventional baseplate materials, such
as copper, do not provide adequate performance and reliability
for high power applications. In contrast, aluminum metal matrix
composite (Al-MMC) baseplates provide an enabling technology for
PEBB modules. A PEBB is a universal power processor which will
convert any electrical power input to any desired form of voltage,
current and frequency output. The baseplate provides the thermal
management system, in addition to being the mechanical support
structure for the module. This program will establish Al-MMC base
plates as the preferred thermal management solution for high power,
compact, low cost and highly reliable electronic power modules.
Manufacturing processes will be optimized, production costs reduced,
and processes for fabricating components with more complex geometries
will be developed and demonstrated.
Benefits:
An overall objective of the Navy MANTECH Program is to significantly
improve the affordability of Navy systems by engaging in manufacturing
initiatives that address the entire system life cycle. The Office
of Naval Research wants to ensure the availability, affordability
and performance of metal matrix substrates, a critical component
for the next generation of advanced Naval power control applications.
This program will benefit the Navy by providing affordable MMC
baseplates with high thermal and mechanical performance, which
will lead to a substantial increase in the reliability of PEBB
modules. With this increase in reliability and efficiency, savings
will be realized through reduced repair and maintenance costs
of these weapon systems.
PEBB modules will replace complex power electronic
circuits, since they will offer reduced design complexity, shorter
time-to-market, and lower cost. They will have a 10x increase
in power density, a 10x increase in reliability and a 5x decrease
in system size and weight. Industry-wide commercialization of
PEBB modules is required to meet the affordability goal of $0.06/Watt
for Naval applications.
Applicable Weapon Systems
Cost-effective power control and distribution is the key to
implementing electric drive on future Naval platforms, like the
DD-21. Technology development programs like PEBB, IPS (Integrated
Power System) and ERS (Electrically Reconfigurable Ship) have
demonstrated the technology and are studying the cost implications
of a shift to electric propulsion/space control. MMC substrates
are an enabling technology for these power controls.
Technical Approach
ACI has contracted with DMC2 (formerly Lanxide)
to develop a high performance baseplate for power modules. These
baseplates will feature integrated cooling pins for improved thermal
management of PEBBs.
The development of this manufacturing technology
will be accomplished by:
-
Developing fabrication processes to produce
baseplates with high thermal conductivity, high strength and
complex geometry in the lab
-
Transitioning these processes to the production
floor
-
Instituting additional cost reduction methods
into production line
-
Demonstrating the baseplate cost reduction
effort utilizing a production run
-
Verifying the thermal and mechanical performance
of the production baseplates
