Power stack design optimization & evaluation kits

Mersen is your preferred partner to assist you during the development phase of your power stack design optimization.

When it comes to designing power inverters and converters, our customers require power stages or power stacks with enhanced power density (kW/liter) while minimizing conversion losses (Efficiency %), reducing cost ($/kW) and reducing size and weight of the overall system.

Thanks to its undisputed reputation in bus bar, cooling, fusing, capacitor design, and manufacturing, Mersen is your preferred partner to assist you during the development phase of your Silicon (Si), Silicon Carbide (SiC) or Gallium Nitride (GaN)-based power stack, bringing a technical cross-expertise on these 4 key products to push the optimization to the limit.

Who benefits from power stack design optimization?

Power stack design optimization and testing can be performed for various types of companies and specialists : 

• Inverter / Stack design-houses with limited or no production capability. 
• OEM / stack and inverter manufacturers: specialists and generalists.
• System Integrators for whom defining converters is not core business.

We place our customers at the heart of power stack design optimization to provide highly personalized services.

The most appropriate topology for the ideal power stack design & optimization

Whereas the final application ultimately drives the inverter operating point setting, our customers are designing the most appropriate topology and control to power this application. From this topology, Mersen is capable of turning a virtual CAD design into a real piece of technology thanks to tight co-development work.

Using multiple power stack design optimization iterations, Mersen is helping their customers achieve the best possible design, taking into account both, mechatronics and electronics constraints and challenges.

A complete tool-set of simulation for high-level of power stack design & optimization

Mersen uses a complete tool-set of simulation software in order to compute any designs in all physical dimensions: Mechanical, Thermal, Electrical, Electromagnetics. These tools allow us to anticipate the multi-physics interactions between all the components and thus to select these components in an optimal mix.

From a few prototypes to volume manufacturing, Mersen assists you for power stack design optimization during: 

• the development phase, 
• the testing, 
• the qualification followed by the sampling, 
• the volume ramp-up 
• and finally the industrialization of your Silicon (Si), Silicon Carbide (SiC) or Gallium Nitride (GaN)-based power stack.

• Dimensions, footprint, geometry
• Circuit topology: 3-level, NPC, ANPC, bi-directional, DC-DC, back-to-back…
• Gate driver: hard switching, soft switching, zero-voltage switching (ZVS)
• Cooling solutions: Air, liquid, heat-pipe…
• Power range, current rating
• Switching Frequency F_sw
• Voltage: 650V, 1.2 kV, 1.7 kV, 3.3 kV modules or more
• Semiconductor technology: SiC MOSFET, Si IGBT, GaN HEMT…
• AC-filtering
• And more according to the demand.

Our center of excellence for power stack design optimization, including assembly / test services for low and medium volumes is located in the United States. The vast majority of the constituent parts used for stack assembly are designed and manufactured in Mersen facilities all over the globe with dual or triple sourcing capability. Our partners and tier-one suppliers also offer dual sourcing strategies.

Our power stack manufacturing footprint includes:

“Stack Lab”: Prototyping and small series  

• Located in Rochester, NY – USA

Pilot Line: Volume ramp-up and mid-size series

• Located in Rochester, NY – USA
• Equipped with an automatic test bench and customer specific power loads

Series Line(s): Volume manufacturing

• Customer specific
• Local-to-local approach: operating in North or South America, Europe, or India according to the final customer supply-chain strategy.

Power stack design optimization includes power stack evaluation kits. Mersen SiC Power Stack Evaluation Kits help inverter designers save time and confusion in selecting individual components and can greatly benefit from a solution that is optimally pre-designed for their specific application.