For hybrid and electric drive passenger cars to reach mass market adoption, their cost must be reduced so that they are nearer parity with gasoline and diesel powered vehicles. Delphi's research and development is focused on reducing the cost of inverters, DC-DC converters, and on-board chargers to meet the U.S. government cost targets. Technical innovations are being developed to increase the inverter temperature capability, which will enable the use of engine coolant for inverter cooling, eliminating the need for the secondary cooling loop. This is being accomplished by a novel power semiconductor packaging technique known as double sided cooling, allowing the cooling system to be in direct contact with both the bottom and the top side of the power semiconductor package. Work on new power switch packaging, wide bandgap power devices and high temperature bulk capacitors shows promise of performance improvements and cost reduction. Couple these activities with attention to common high volume manufacturing processes and lower cost power electronics are just a few years away. The conclusions are: (1) The path to increased powertrain electrification is through cost-effective technical innovation; (2) Powertrain electrification solutions support the U.S. 2017 - 2025 fuel economy and emissions standards; (3) The needed lower-cost power electronics fit the high volume production and supply base strengths of Tier 1 suppliers; (4) Standardization of requirements across multiple OEM customers will lower costs by accelerating volume production; (5) Optimizing component designs for both performance and volume production will substantially reduce the cost and increase the competitiveness of electric drive systems, when compared with either traditional or with other alternative powertrain systems.


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