Scientists have developed a low-cost, compact power module that can be used in data centers, microreactors, and heavy-duty vehicles. Called Ultra-Low Inductance Smart (ULIS) power module, the efficient innovation is capable of achieving five times greater energy density than predecessor designs in a smaller package.
Developed by the National Renewable Energy Laboratory in the U.S., the module can help manufacturers build and power more efficient, compact, and lighter technologies.
Scientists revealed that the 1200-volt, 400-amp power module is suitable for use in power grids and even heavy-duty vehicles such as next-generation aircraft and military vehicles.
ULIS boasts parasitic inductance
They pointed out that the ULIS boasts parasitic inductance—resistance to changes in electrical current, which is the primary hurdle to any electrical conversion, seven to nine times lower than any current state-of-the-art silicon carbide power module. Its ultrafast, ultraefficient switching of electrical current into usable forms allows ULIS to “squeeze” more usable power out of the electricity supply. This makes it a compelling solution to the world’s energy demand problem.
“We consider ULIS to be a true breakthrough,” said Faisal Khan, NREL’s chief power electronics researcher and the principal investigator for the project. “It’s a future-proofed, ultrafast power module that will make the next generation of power converters more affordable, efficient, and compact.”
Suited for high-intensity applications, like aviation and military operations
Furthermore, Khan explained, ULIS is uniquely suited for high-intensity applications, like aviation and military operations, because the powerful, lightweight module also monitors its own state of health and can predict component failure before it occurs. For planes flying 30,000 feet above sea level or military vehicles traveling through combat zones, that level of reliability can mean the difference between life and death.
“ULIS was a truly organic effort, built entirely in-house here at NREL,” Khan said. “We are very excited to demonstrate its strengths in real-world settings.”
Unlike typical power modules, which assemble semiconductor devices inside a brick-like package, ULIS winds its circuits around a flat, octagonal design. The disk-like shape allows more devices to be housed in a smaller area, making the overall package smaller and lighter.
At the same time, novel current routing allows for maximum magnetic flux cancellation, contributing to the power module’s clean, low-loss electrical output—in other words, its ultrahigh efficiency, according to a press release.
“Our biggest concern was that the device switches off and on very quickly, and we needed a layout that wouldn’t create a chokepoint within the design,” said Shuofeng Zhao, an NREL power electronics researcher who designed ULIS’ flux cancellation architecture.
Scientists also revealed that a breakthrough allows ULIS to function wirelessly, as an isolated unit that can be controlled and monitored without external cables. That modular, Lego-like nature means it can slot into machines as different as data center servers, advanced aircraft, and military vehicles.
The patent for this low-latency wireless communication protocol, spearheaded by NREL power electronics Sarwar Islam, is pending.