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DISCLAIMER : System Plus Consulting provides cost studies based on its knowledge of the manufacturing and selling prices of electronic components and systems. The given values are realistic estimates which do not bind System Plus Consulting nor the manufacturers quoted in the report. System Plus Consulting is in no case responsible for the consequences related to the use which is made of the contents of this report. The quoted trademarks are property of their owners.
© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 1
Electronic Costing & Technology Experts
www.systemplus.fr21 rue la Nouë Bras de Fer44200 Nantes – France Phone : +33 (0) 240 180 916 email : [email protected]
September 2016 - Version 1 - Written by Elena Barbarini
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 2
Glossary1. Overview / Introduction 4
– Executive Summary
– Reverse Costing Methodology
2. Company Profile 7
3. Physical Analysis 9– Synthesis of the Physical Analysis
– Module design
3.1 Generator Inverter 13
3.1.1 Module teardown
– View and dimensions and marking
– Package Opening & Cross-section
3.1.2 IGBT
– Dimension, process
– Cross-section
3.1.3 Diode Analysis
– Dimension, process
– Cross-section
3.2 Boost Converter & Motor Inverter 55
3.2.1 Module teardown
– View and dimensions and marking
– Package Opening & Cross-section
3.2.2 IGBT
– Dimension, process
– Cross-section
3.2.3 Diode Analysis
– Dimension, process
– Cross-section
4. Manufacturing Process Flow 85– Overview
– IGBT Process Flow & Fabrication unit
– Diode Process Flow & Fabrication unit
– Package Process Flow & fabrication unit
5. Cost & Price Analysis 90– Synthesis of the Cost Analysis
– Main Steps of Economic Analysis
– Yields Explanation
5.1 Cost & price Analysis Generator Inverter 93
– IGBT Wafer Cost & die cost
– Diode Wafer Cost & die cost
– Module Wafer Cost & die cost
– Module price
5.2 Cost & price Analysis Boost converter & motor inverter 113
– IGBT Wafer Cost & die cost
– Diode Wafer Cost & die cost
– Module Wafer Cost & die cost
– Module price
6. Toyota Prius vs Chevrolet Volt Power Module 133
Contact
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 3
• This full reverse costing study has been conducted to provide insight on technology data,manufacturing cost and selling price of the IGBT power modules integrates in the PCU of the ToyotaPrius 4.
• For its latest Prius 4 Toyota designed a new PCU. The PCU is assembled with two types of powermodules, one for the motor inverter and the other for the boost converter and generator inverter.
• The module integrates the latest packaging of Toyota power card with double side cooling. Themodule allows an optimization of the modularity and scalability of the PCU’s inverters and a betterthermal dissipation thanks to the use of copper heatsink and spacers. The power cards can be placedin parallel to have a single thermal dissipation circuit in a limited space. This package includes twopairs of IGBT and FWD wire bonded and it is plastic molded.
• The report offers a deep technical analysis of the module structure and packaging and of the IGBT anddiode dies.
• Based on a complete teardown analysis, the report also provides an estimation of the production costof the package, IGBT and diode.
• Moreover the report proposes a comparison with the Chevrolet Volt Power module.
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 4“Toyota’s Challenge of Applying SiC Power Semiconductors to Environmentally Friendly Vehicles and its update” ISiCPEAW 2016
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 5
• Module dimensions: 105 mm x 57 mm
Module marking
IGBT and diode of generator inverter
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 6
Module Overview
Module marking
Pins Pins cross section
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 7
Module: Optical view
Wire bonding
IGBT
Collector plate
Diode
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 8Module Cross-Section Optical view
Module Cross-Section Optical view
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 9
IGBT Die Overview
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 10Die Cross-Section – Optical View
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 11
Die Cross-Section – SEM View
Die Cross-Section – SEM View
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 12Die Cross-Section – SEM View
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 13
Diode Die Overview
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 14
Diode manufacturing1 metal layer, backside
Probe testDicing
IGBTDiode
Assembly in packageFinal test
Power Module
IGBT manufacturing1 metal layer, trench, backside
Probe testDicing
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 15
• The wafer cost is between $xxx and$xxxaccording to yield.
• The main part of the wafer cost is due to theconsumables with xxx%. The equipment partcounts for xxxx%.
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 16
• The dies cost is between $xxx and $xxaccording to yield.
– Silicon cost accounts for xx% of the costfor medium yield .
– The probe test, backgrinding and dicingrepresent xx% of the cost for mediumyield.
– The scrap cost (xxx% ) is the total of allthe losses during probe test and dicing formedium yield.
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 17
• The die cost is between $xxx and $xxaccording to yield.
– Silicon cost accounts for xx% of the cost.
– The probe test, backgrinding and dicingrepresent xx% of the cost.
– The scrap cost (xx% ) is the total of all thelosses during probe test and dicing.
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 18
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 19
• The assembled module cost is estimated between $xxx and $xxx according to yield.
• The dies cost (Silicon cost) accounts for about xxx%.
• The copper cost accounts for xxx% of the cost.
• The added value cost is $xx (x%).
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 20
• The module manufacturer price is estimated between $xxx and $xxx.
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 21
Chevrolet Volt IGBT & Diode
Toyota Prius IGBT & Diode
Full Reverse Costing report: EUR 3,490*
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Founded in 1998, Yole Développement has grown to become a group of companies providing marketing, technologyand strategy consulting, media and corporate finance services. With a strong focus on emerging applications usingsilicon and/or micro manufacturing, the Yole Développement group has expanded to include more than 50collaborators worldwide covering MEMS, Compound Semiconductors, LED, Image Sensors, Optoelectronics,Microfluidics & Medical, Advanced Packaging, Manufacturing, Nanomaterials, Power Electronics and Batteries & EnergyManagement.The “More than Moore” company Yole, along with its partners System Plus Consulting, Blumorpho and KnowMade,support industrial companies, investors and R&D organizations worldwide to help them understand markets andfollow technology trends to grow their business.
CUSTOM STUDIES• Market data & research, marketing analysis• Technology analysis• Reverse engineering & costing services• Strategy consulting• Patent analysisMore information on www.yole.fr
MEDIA• i-Micronews.com, online disruptive technologies website and its weekly e-newsletter, @Micronews• Communication & webcasts services• Events: Yole Seminars, Market BriefingsMore information onhttp://www.i-micronews.com/media-kit.html
TECHNOLOGY & MARKET REPORTS• Collection of technology & market reports• Manufacturing cost simulation tools• Component reverse engineering & costing analysis• Patent investigationMore information onhttp://www.i-micronews.com/reports.html
Please process my order for “Toyota Prius Power Modules” Reverse Costing Report
Toyota Prius 4 Power Module
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© 2016 by SYSTEM PLUS CONSULTING, all rights reserved. 22
• Reverse costing analysis represents the best cost/price evaluation given the publically available data, and estimatescompleted by industry experts.
• Given the hypothesis presented in this analysis, the major sources of correction would lead to a +/- 10% correction on themanufacturing cost (if all parameters are cumulated)
• These results are open for discussion. We can reevaluate this circuit with your information. Please contact us:
• Consulting and Specific Analysis
– North America: Steve LaFerriere, Director of Northern America Business Development
Email: [email protected]
– Japan & Asia: Takashi Onozawa, Representative Director, Yole KK
Email: [email protected]
– RoW: Jean-Christophe Eloy, CEO & President, Yole Développement
Email [email protected]
• Report business
– North America: Steve LaFerriere, Director of Northern America Business Development
Email: [email protected]
– Europe: Lizzie Levenez, EMEA Business Development Manager
Email: [email protected]
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Email: [email protected]
– Greater China: Mavis Wang, Business Development Director
Email: [email protected]
• Financial services
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Email: [email protected]
• General
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