The purpose of the information in this presentation is to guide ICA programs and provide members with information to make independent business ...
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The purpose of the information in this
presentation is to guide ICA programs and
provide members with information to make
independent business decisions.
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 1
Antitrust Guidelines for Copper Industry
Trade Association Meetings
The following guidelines with respect to compliance with antitrust laws of the United States, Japan and European Community1
are intended to govern the conduct of participants in copper industry trade association meetings, both at the meeting itself and
in informal discussions before or after the formal meeting.
Price: Competitors should not discuss future prices (including terms of sale) of their products. There is no blanket prohibition
against the mention of or reference to current or past prices but limits must be observed. Such references or mentions should
occur only when necessary in connection with the development of association programs. For example, reference to a particular
price level in comparing the cost of a copper product to a competing product is permitted. Whenever possible, such references
should be discussed in advance with legal counsel.
Competitive Information: Competitors should not discuss the market share of a particular copper producer or copper
fabricator’s products. Furthermore, nothing should be said at a meeting which could be interpreted as suggesting prearranged
market shares for such products or producer production levels. The overall market share of copper products may be discussed
with regard to competition with non-copper products and general market acceptance.
New Products: Competitors should not encourage or discourage the introduction of a new product by another competitor or
reveal a particular copper company’s plans to change the production rate of an existing product or to introduce a new product.
No company should disclose to another company whether it is in a position to make or market a new product. New products
may be discussed in a technical manner or from the standpoints of competition with non-copper products and general market
acceptance. In addition, proposed methods for and results of field and laboratory testing can be considered.
The Role of Legal Counsel: Legal counsel attends association meetings to advise association staff and other meeting
attendees regarding the antitrust laws and to see that none of the matters discussed or materials distributed raise even the
appearance of antitrust improprieties. During the course of a meeting, if counsel believes that the discussion is turning to a
sensitive or inappropriate subject, counsel will express that belief and request that the attendees return the discussion to a less
sensitive area.
A paper entitled ‘Copper Industry Trade Associations and Antritrust Laws’ is available upon request.
10/92, 5/93, 10/10
1. Other foreign competition laws apply to International Copper Association, Ltd. (ICA)’s activities worldwide.
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 2
Copper Demand in Power
Electronic Devices
Luke Gear, Senior Technology Analyst
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 3Booming EV Market Brings Opportunities
Plug-in car forecast (millions) Electric car markets are booming – growing from just over 4% of
> 80% the global auto market today to over 80% in 2040 (IDTechEx).
70
As a result, many new materials opportunities are emerging in the
electric vehicle supply chain. In this presentation we focus on
power electronics, critical for the operation of EVs and
renewables, and a focal point for innovation in itself representing a
plethora of new materials opportunity.
> 4%
0
2020 2030 2040
Forecast calculated in 2021. Source: IDTechEx
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 4What is ‘Power Electronics’ in an Electric Vehicle
‘Power electronics’ is the control and conversion of power using solid-state electronics. For electric vehicles, power
electronics devices include the onboard charger, the main inverter and DC DC converters.
Onboard Charger
Main Inverter
(AC / DC Converter)
HV Battery Electric Motor 100kWp - 200kWp
350VDVC
DC DC
Grid Supply
120 - 240V AC 200 - 400VDC
DC AC
350V – 48V DC / DC converter
LV System for
Graphic: IDTechEx infotainment,
air con, radar
etc…
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 5The Transition to Silicon Carbide (SiC) & Gallium
Nitride (GaN)
Semiconductor Material Properties
High Voltage GaN
− High temperature operation - greater areal power Operation
SiC
density and reduction in die area / package size. Electric Field (MV /
cm) Si
5
4
− High frequency operation - potential for smaller 3
passive components such as capacitors. 2
Thermal
Energy Gap (eV) Conductivity
1 (W/cm C)
0
− High voltage operation is a trend in premium EVs
(Porsche Taycan, Lucid Air at 800-900V). It enables High Temp
Applications
downsizing of cables allowing weight savings, and
faster charging. Electron Velocity Melting Point
(x10^7 cm/s) (x1000C)
High Freq
Switching
Data source: InRel - NPower
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 6Applications for Silicon Carbide & Gallium Nitride
Inverters and converters in electric vehicles, wind turbines and commercial solar farms are facing a transition to Silicon
Carbide.
Application Power (W)
EV main
1,000,000 inverters Wind turbine
converters
Silicon Carbide
100,000
Commercial
10,000 solar inverter
Onboard
chargers
1,000 Micro solar
Gallium Nitride inverter
100
10 Phone, laptop, TV chargers
1
Graphic: IDTechEx Application Voltage
20V 30V 100V 300V 600V 1200V 3300V
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 7The Transition so Far
Silicon Carbide inverters are adopted across a variety of electric Market share of main inverters which use
vehicles. Silicon Carbide (SiC) in electric cars
Forecast starts
100%
o Tesla Model 3 (350V) (2018)
o Tesla Model Y (2020)
o BYD Han (Q3 2020). 75%
o Tesla Model X and S refresh (2021)
SiC
o Lucid Air (900V) (H1 2021). 50%
Si IGBT
o Delphi is suppling a ‘major OEM’ with SiC inverters from
2022. VW? (Audi e-tron, Porsche Taycan at 800V…)
25%
The general trend to higher voltages (> 800V) in cars and heavy-
duty vehicles will help drive SiC MOSFET inverter uptake. 0%
2015 2020 2025 2030
Source: IDTechEx
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 8Inverter & Power Module Packages
The main active component of the inverter is the power module packaging. Alongside busbars, wires and connection
plates, this is a key source of copper in the inverter.
Si IGBT Inverter Package Power Module Package
Open view of standard Si IGBT power modules from Infineon.
Source: Munro & Associates
Exploded sketch of a typical inverter. Source: The International Journal
of Life Cycle Assessment (2019) 24:78–92
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 9Where is Cu in a Power Module Package?
Below we show a schematic cross section of a conventional Si IGBT package.
Busbar
Gel filling New material opportunities
Wire bond
Semiconductor die
Die: transition towards Silicon Carbide
Wire bonding: going beyond Al bonding towards Cu bonding or
Die-attach material wire bonding-free methods.
Substrate Cu Substrate: Higher performance ceramics or metal insulator
substrates.
Substrate-attach Thermal grease: eliminate if possible, especially in direct cooling
material Baseplate Cooling: transition to double-sided cooling.
Thermal Interface Material
Die-attach: transition away from solder e.g. Ag sintered material.
Heat Sink Substrate-attach: might require non-solder solution in very
demanding conditions.
Graphic: IDTechEx
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 10Size Reductions to Inverter Package
With the release of the Model 3 in 2018, Tesla became the first company to add SiC metal-oxide-semiconductor field
effect transistors (MOSFETs), sourced from ST Microelectronics, in an in-house inverter design.
Semiconductor die area (mm2) Comparison of Inverter Packages
100 300%
75
200%
SiC (2018 Model 3)
50
100% Si IGBT (2019 Nissan
25
Leaf)
0 0%
Infineon Si IGBT ST Volume Weight Power
Microelectronics Density
SiC
Source: IDTechEx Source: Munro & Associates, IDTechEx
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 11Copper Lead Frames Replace Aluminum
Cu lead frames are an emerging technique, used by Tesla and introduced by Mitsubishi, to replace the multiple wire
bonds that allow the semiconductor chips to communicate. Al wire bonds are a common point of failure with power
cycling, whereas Cu lead bonding lasts up to 10x longer by eliminating the highly localized hot spots on the chip surface.
Cu in Tesla SiC Inverter (based on grams)
1%
Direct Bond Cu
Substrate
Lead Frame
30%
44% Mosfet Terminals
Phase Lead
Terminal
Connection Panel
25%
0.1% Capacitors
0.3%
Source: IDTechEx Image source: chargedEVs, Mistubishi Electric
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 12Capacity-additions by Power Rating: Wind, Solar, EVs
Below power output capacity additions of wind and solar is compared with the combined motor output of electric cars
each year. Electric cars, wind and solar farms have inverters with a copper intensity (kg per kW) - copper demand is
proportional to these forecasts.
Global renewable energy capacity-additions Capacity additions by power rating (GW)
(GW) 4,000
500
442 3,500
405
400 371 3,000
340
312 2,500
300 262
286 Solar
241 2,000
221 Wind Wind
203
200
186
Solar 1,500 Electric Cars
1,000
100 500
0
0
2015 2020 2025 2030
2020 2025 2030
Based on an IDTechEx regression analysis of IRENA, IEA, DNG.VL Source: IDTechEx
forecasts. Source: IDTechEx
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 13Copper Demand in Power Electronics Devices
− In 2030, around 20kT of Cu per year will be required for renewable energy and electric car power electronics
devices.
Cumulative Cu demand from power
Cu demand from power electronics devices (kT) electronics devices (kT)
25 120
19.6 Wind Inverters 97 Wind Inverters
20 100
Solar Inverters 80 Solar Inverters
15
Electric Car DC DC 60 Electric Car DC DC
10 Converters Converters
6.7 Electric Car Onboard 40 Electric Car
Chargers Onboard Chargers
5
2.2 Electric Car Inverters 20 Electric Car
0.6
Inverters
0 0
2015 2020 2025 2030 2015 2020 2025 2030
‘Electric car’ includes plug-in hybrid and pure battery-electric cars. Wind farm converters not included. Source: IDTechEx
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 14Long-term Snapshot
− In 2040, 45kT of Cu per year will be required for electric car inverters.
Cu demand from electric car inverters (kT) Cumulative Cu demand from electric car
80 inverters (kT)
69.0 450 425
70
SiC 400
60 SiC
350
Si IGBT Si IGBT
50 44.7 300
No SiC 250
40
transition
200
30
150
20
100
10 50
0 0
2015 2020 2025 2030 2035 2040 2015 2020 2025 2030 2035 2040
‘Electric car’ includes plug-in hybrid and pure battery electric cars. Source: IDTechEx
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com Slide 15You can also read
