INTERNATIONAL RECTIFIER - THE POWER MANAGEMENT LEADER

Automotive Capabilities

By focusing on technological innovation and the highest standards of quality and reliability, International Rectifier remains a worldwide leader in the manufacture of power semiconductors. Our goal is to provide customers with a competitive advantage and maximize shareholder equity through the research and development (R&D) of the best products and services.

International Rectifier Newport Wales, Ltd.

Design Technology
Testing and Validation
Quality and Reliability
Manufacturing Capability

Design Technology

Thermo-Mechanical Design
Finite Element Analysis to determine thermal performance of the system
In-house mechanical design, for better integration of electrical, physical and thermal requirements
Substrate technology
Solder processes
Peak temperature simulation and validation

Control Design
Design of digital and analog circuitry
Design and implementation of control software
Electrical and motor simulation
System level architecture development
Control algorithms for all motor types

EMS Intellectual Property
53 patents granted or pending
Electrical Design
In-house expertise on silicon switches
Integration of inverter and driver circuitry
Feedback circuitry "designed in"
Electronic and motor simulations
Power technologies and trade-offs
Proprietary power dissipation models
Testing and validation

System Design
Printed circuit board (PCB) layout for improved EMI emissions and susceptibility in high-current environments
Software
Prototype assembly
Field oriented AC motor control (sensored and sensorless)
Sinusoidal and trapezoidal control of BL-DC motors
Extended Kalman estimator for sensorless BL-DC motors
Phase advance algorithms for BL-DC motors
Expertise in conducting EMI, ESD, thermal shock, endurance and ON/OFF tests

Testing and Validation

Full system inspection for every manufactured unit
Tested for all rugged automotive environmental conditions
Only quality-approved electronic parts used
Full analytical software design testing

Proven durability and endurance for harsh automotive environments
Ease of repeatability with a fully-automated test environment
QS9000 approved
Failure Analysis (FA) capability

Quality and Reliability


International Rectifier has established a complete quality and reliability system as required from an automotive system supplier. IR’s Quality System establishes policies and sets standards across all manufacturing locations, building on the foundation of world-class standards with bedrock IR processes and programs. All primary IR manufacturing facilities are certified to ISO9001 and QS9000. Copies of ISO9000/QS9000 certificates are available upon request.

IR semiconductor products for automotive applications are qualified to the Production Part Approval Process (PPAP) as required by ISO/QS standards. As part of the PPAP qualification process, IR employs numerous test methods and procedures to ensure the highest quality products such as:
Stress test qualification for discrete semiconductors
Potential Failure Mode Effects Analysis (FMEA)
Statistical Process Control (SPC)
Gage repeatability
Reproducibility
Customer-specific testing is also prerformed upon request

Quality systems include extensive testing and validation procedures including:
Full system inspection for every manufactured unit
Tested for the full automotive temperature range of -40°C to +125°C
Full analytical software design testing
Proven durability and endurance for harsh automotive environments
EMS/EMC testing
Ease of repeatability with a fully automated qualification test environment
Failure Analysis (FA) capability

Manufacturing Capability


International Rectifier’s world class manufacturing facilities include wafer fabs, semiconductor assembly, advanced power electronics, hybrid module and SMT system assembly. International Rectifier has QS9000 and ISO14001 certified wafer fabrication facilities in Temecula and El Segundo, California, Newport, Wales as well as Turin, Italy, providing state-of-the-art die, test and tape and reel capabilities. Our Known Good Die (KGD) process guarantees die quality through 100% testing. Using true Kelvin connections to enable measurements at high current, the die are examined in a proprietary test nest. This results in measurably higher yields in module assembly.

IR maintains world-class facilities worldwide, dedicated to the superior manufacture of components for the automotive industry. IR maintains the standards of QS9000, ISO/TS 16949 and ISO14001. In addition, QS9000 certified facilities also contain a Class 10,000 clean room environment. IR’s highly skilled team of technicians and operators use fully-automated, high-volume manufacturing processes focused on zero defects for demand fulfillment.

Our facilities all have the necessary equipment, including printing, drying, dynamic trimming and pick-and-place for production of high-volume thickfilm hybrid circuits. IR Automotive produces power generation electronics sold to major first tier automotive suppliers for chassis and powertrain applications. Our hybrid circuits are assembled in plastic housings and soldered with specially designed flame-soldering equipment.

IR has design expertise on a variety of material systems for electronic controls and we manufacture some of our own ceramic substrates. Material systems include:
Thick film
Isolated metal substrate
Direct bonded copper (AIN or SiN or AI203)
Leadframe on silicone insulator
Surface Mount Technology (SMT)

Newport Facility
International Rectifier's Facility in Newport, Wales


IR El Segundo Wafer Fab

Temecula Facility
IR Temecula, CA Wafer Fab

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Automotive Capabilities
Design Technology
Testing and Validation
Known Good Die (KGD) Testing
Quality and Reliability
Manufacturing Capability
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Design Tips
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