German research institute Fraunhofer IZM, in collaboration with Porsche and Bosch, has developed a next-generation inverter capable of delivering sustained high power for electric vehicles, with potential applications across a broad range of platforms including electric sports cars and heavy-duty trucks.
Dubbed the “Dauerpower inverter,” the new technology achieves a peak efficiency of 98.7% and delivers a continuous output of around 600 kilowatts, or 815 horsepower. This output level exceeds by roughly 50% the power handled by conventional diesel-powered heavy trucks, according to Fraunhofer IZM.
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“The Dauerpower inverter can even handle 720 kW or 979 horsepower for short bursts,” the research institution said in a press release. “That will, in turn, set a new benchmark for high-end electric sports cars.”
The inverter, which was initially introduced last year, features a modular design with compact individual components, allowing it to be integrated into a wide variety of electric vehicle architectures. Key to the system’s performance is its use of silicon carbide (SiC) transistors, which are embedded directly onto a ceramic substrate using a novel prepackaging process developed at Fraunhofer.
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“Semiconductor embedding allows us to place the supply and return conductors far closer to each other and reduce leak inductance,” said Dominik Seidenstücker, a lead scientist on the project. “The module’s lower leak inductance allows faster switching transition. This, in turn, means even lower losses in the semiconductors.”
The cooling system has also been a focus of innovation. The module incorporates 3D-printed copper cooling elements and silver-sintered mounts to optimize heat transfer. An additional 3D-printed aluminium structure facilitates water-based heat dissipation. The inverter operates with a coolant flow of 10 liters per minute, with a pressure loss of only 150 millibars.
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“With cooling technology this advanced, the inverter remains in the optimum operating temperature even when under heavy load,” Fraunhofer concluded. “One could say that the Dauerpower inverter knows how to keep its cool.”
The innovation is expected to contribute to further performance improvements in electric drivetrains while enhancing energy efficiency across various sectors of electric transportation.
