New IGBT/FRED Technology from International Rectifier Re-Defines AC Motor Control Speed and Efficiency

New process technology increases useful AC motor speed range by reducing dead-time by a factor of 3 with 20% lower power loss

EL SEGUNDO, CA. July 2001 - International Rectifier, IR® (NYSE: IRF) today announced a new process technology for IGBTs (insulated gate bipolar transistor) and FREDs (fast recovery epitaxial diode), that deliver 70% faster turn-off time than previous generation devices and more than 20 percent lower power loss than the best product available on the market. The new technology is optimized for IGBTs and FREDs used in bridge-type inverters found in motor drives, welders and uninterruptible power supplies (UPS).

The new process technology enhances device turn-off performance. For example, new devices are capable of 0.3ms turn-off time compared to 1.6ms for previous generation devices. When compared to existing devices, the new technology increases useful AC motor speed range, reducing the inverter dead-time by a factor of 3 and expanding proportionally the PWM duty cycle range and the modulated frequency range. These switching speed improvements extend the modulation capability of sensor-less vector drives for AC induction motors, making it possible to improve low-speed performance. The consequent improved low speed control extends AC induction motors use into applications that previously required higher performance motors.

Since power loss is reduced, smaller heat sinking and lower system costs are possible, or higher power levels can be delivered in smaller package outlines. For example, Super-247™ Co-Pack IGBTs made with this new technology can handle up to 7.5 HP and provide a low cost, 10ms (at 15VGE) short-circuit rated solution for applications that currently use modules in larger packages, saving as much as 74% space.

In addition, lower switching energy (Etot) and delay time (Td(off) ) combine with hyperfast, yet ultra soft recovery diode characteristics to reduce conductive noise by 3 to 5dB mV in the 1 to 30MHz range, resulting in smaller output filters and lower filter costs.

Gate characteristics have three times greater noise immunity, and dv/dt induced turn-on current is reduced by a factor of 20, when compared to competitive devices. Therefore, the new-technology IGBT Co-Pack devices do not require negative bias to turn off. This eliminates the negative bias power supply, further reducing circuit cost and complexity.

"By eliminating the negative bias supply, the new IGBTs can be driven with high voltage gate driver ICs such as the IR2213 or IR2233. The IGBTs are perfect companions for IR's integrated and fully-protected gate drivers in simple, cost-effective motor drives," said Alberto Guerra, Motor Drive Sector Director at International Rectifier.

On-state losses have a positive temperature coefficient, which make it easier to parallel multiple devices while maintaining balanced temperatures. Switching loss is less dependent on temperature than previous generation devices. This combination will allow for less de-rating of the system for higher operating temperatures.

Two IGBT/FRED Co-Packs using this new technology are now available for sampling. Rated at 1200V, the two devices have been optimized for applications such as 400 to 480VAC input bridge-type inverters for power levels up to 7.5HP.

The IRGPS60B120KD is optimized for frequencies up to 25kHz and is used for motor drives. The IRGPS40B120UD Co-Pack IGBT is optimized for frequencies up to 50kHz and is designed for UPS, welding, induction heating and switched mode power supplies (SMPS).

Four of the new process devices switched 8kW at 50kHz in a dual-ended forward converter and replaced eight 1000V MOSFETs in the same application, providing a very cost effective solution and cutting the size of the circuit by 50%.

"International Rectifier's new IGBT and FRED Co-Pack devices reduce or eliminate negative voltage power supply and snubber circuits, and have outstanding thermal performance. These characteristics combine to enable system cost savings of 10 to 20 percent when compared to previous generation products. The new process technology will be used as a platform for an entire family of high efficiency, energy-conserving die, discretes, Co-Packs and modules to cover a wide range of power levels," said Guerra.

Pricing and Availability

Pricing for IRGPS40B120UD and IRGPS60B120KD is US $8.32 each in 10,000-unit quantities. Samples will be available in July 2001 with volume production in August 2001.

Part number Package Voltage IC @ TC = 100°C(A) V CE(ON) typ.@ TJ = 125°C @15VGE (V) Eswitch @TJ= 125°C (mJ) Application
IRGPS40B120UD Super-247äCo-Pack 1200V 40 3.12 4.77 Inverter, power conversion
IRGPS60B120KD Super-247äCo-Pack 1200V 60 2.50 12.50 Inverter, motor drive up to 7.5hp

Trademark Notice

IR® and HEXFET® are registered trademarks of International Rectifier Corporation. All other product names noted herein may be trademarks of their respective holders.



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