Toyota Prius 4 PCU modules integrate IGBT and freewheeling diodes onto innovative double side cooling packaging for hybrid electric vehicles, allowing better thermal dissipation, modularity and scalability of the system.
For its latest Prius 4 Toyota has designed a new power control unit (PCU). The PCU has two types of power module, one for the motor inverter and the other for the boost converter and generator inverter.
The module integrates Toyota’s latest power card packaging, with double side cooling. It allows the modularity and scalability of the PCU’s inverters to be optimized and also enables better thermal dissipation thanks to the use of copper heatsinks and spacers. The power cards can be placed in parallel to have a single thermal dissipation circuit in a limited space.
This package includes two pairs of wire bonded IGBTs and freewheeling diodes and is plastic molded.
This report offers a deep technical analysis of the module structure, packaging, and of the IGBT and diode die.
Based on a complete teardown analysis, the report also provides an estimation of the production cost of the package, IGBT and diode.
Moreover, the report compares the Prius 4 PCU with the Chevrolet Volt power module, analyzing the technical choices of the packaging and the die. This comparison highlights the huge differences in design and manufacturing process and their impact on device size and production cost.
Overview / Introduction
Executive SummaryReverse Costing Methodology
Synthesis of the Physical Analysis> Module designGenerator Inverter> Module teardown> IGBT> Diode analysisBoost Converter and Motor Inverter> Module teardown> IGBT> Diode analysis
Manufacturing Process Flow
OverviewIGBT Process Flow and Fabrication UnitDiode Process Flow and Fabrication UnitPackage Process Flow and Fabrication Unit
Synthesis of the Cost AnalysisMain Steps of Economic AnalysisYields ExplanationCost and Price Analysis Generator Inverter > IGBT wafer cost and die cost> Diode wafer cost and die cost> Packaging cost> Module cost> Module priceCost and Price Analysis Boost Converter and Motor Inverter > IGBT wafer cost and die cost> Diode wafer cost and die cost> Packaging cost> Module cost> Module price
Toyota Prius vs Chevrolet Volt Power Module
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Manufacturing process flow
Supply chain evaluation
Manufacturing cost analysis
Selling price estimate