Heraeus Electronics
Driving Innovation in Power Electronics with Novel Solutions

Dr. Klemens Brunner, President

At the heart of these systems lie mission-critical assembly and packaging materials, as well as their integration and optimisation for a robust power package. The complex modules and electronic devices require a reliable supplier with high volume production capacity and a proven track record.

Heraeus Electronics is a reckoning force in the power electronics space, known for its broad product portfolio, deep application know-how, and expertise in matching materials. The trusted innovation partner helps clients develop material solutions and bring products to market faster. It has world-class application centres in Hanau, Shanghai, West Conshohocken, Korea, Singapore, and Taiwan, all dedicated to fuelling early material development and testing activities.

An operating company of the Heraeus Group, Heraeus Electronics has a rich legacy of over half a century, developing some of the earliest power electronics materials with reputed German companies. Today, it manufactures products across power electronics, semiconductor and thick film business lines.

All Things Power Electronics Under One Roof

A power electronic device’s performance and reliability depend largely on the interplay of the materials, not just the capabilities of each component. At the same time, designing a power electronics package is an intricate task, requiring elaborate processes and extensive coordination between different stakeholders, like bonding wire specialists and sinter specialists.

Heraeus specialises in the development and integration of different materials, which leads to a powerful matched packaging solution and easy-to-manufacture electronic components. By partnering with the company, manufacturers can access all capabilities under one roof, which makes the process as seamless as possible.

“We have all the capabilities and the technical know-how to design our materials, and the ability to develop a process at the customer’s location. Our complete solution provider approach ensures that each part works perfectly in their factories,” says Dr. Klemens Brunner, president of Heraeus Electronics.

Its broad power electronic materials portfolio includes Metal Ceramic Substrates, Die Attach Solder and Sinter Materials, Bonding Wires and Ribbons, Die Top System for die top connection, Sinter Materials for large area sintering, Sinter and Solder Materials for connecting the module to the heat sink, as well as inorganic encapsulation materials (under development). The extensive breadth of materials, covering everything from substrate to body, coupled with premium engineering services, makes Heraeus the partner of choice for customers.

Innovative Solutions Backed by Best-in-Class Resources

In an industry characterised by dynamism and rapid progression, Heraeus is a trusted innovation partner committed to reducing the time to market for clients using application and testing services and full on-site support. State-of-the-art application centres across Europe, Asia Pacific and the Americas, and the latest machines equip the team to assemble prototypes, conduct performance testing and qualification of new material systems in a production environment, and make changes when necessary.

Backed by modern technologies and the best minds working together, customers can ramp up their R&D process, reduce the development cycle, and improve first-time success rates.

Efficient Solutions for Every Need

Through consistent customer interactions, Heraeus gains insight into their needs and formulates tailored solutions to fulfil their requirements. Decades of institutional knowledge power the team’s problem-solving and troubleshooting capabilities, enabling them to efficiently address challenges.

For instance, if a customer wants to switch from a silicon to a silicon carbide semiconductor, the reliability and operation at higher temperatures can turn into a bottleneck. When they solve the issue of reliability and high temperatures for die attach, a new problem arises.

In these complex scenarios, Heraeus is a true problem solver, fulfilling not just client needs but developing a more robust product. The team is adept at designing solutions that work at very high temperatures and can be deployed in an industrial motor as well as an automobile, which is an order of magnitude more important than standard industrial products.

Regardless of the product requirements, whether it’s compact dimensions compared to standard size or compatibility with automotive applications, Heraeus is prepared to meet the challenge. This level of reliability is truly unheard of elsewhere in the industry.

This capability is supported by high-volume product manufacturing, which facilitates cost-effectiveness for clients. Strategically located factories across three continents allow it to meet the specialised needs of global clients with locally manufactured products with specific configurations. For instance, if a client has factories in China and the U.S. and needs locally manufactured material solutions in each of these locations, Heraeus can meet both needs. All of its factories are automotive-certified and capable of manufacturing parts as per automotive standards. A fully automated production environment ensures consistency in manufacturing and keeps costs in check.

Quality Above All

A dedicated new product introduction team is entrusted with the responsibility of taking a product from the early development phase to manufacturing without compromising on quality or the stability of the processes.

The dedication to quality begins at the material design phase. In the product development phase, design for quality plays a critical role, which is then transferred to the manufacturing phase.

Throughout these processes, automated quality control systems allow for quick response time in case of complaints. Quality teams, specialists and analysis labs in every region guarantee prompt service for all its customers. This is especially beneficial for complaints in the automotive field, where prompt response is a necessity.

Behind every satisfied customer are the collective efforts of its dedicated research and development, product marketing, product management and business development teams that maintain strong relationships with key customers. The highly skilled team members have built a sense of trust and reliability by addressing even the most challenging needs in an effective manner.

“We are a highly customer-centric company. Customers’ R&D teams often reach out to us when they face a challenge, and we come up with a solution together,” says Brunner. “Material development in power electronics takes years, and if after five to six years of development, we discover that the material used was not the right one, millions of dollars spent on development would have been wasted. As their material supplier, we try to get involved in the process from the earliest stages.”

One of Heraeus’ key capabilities is its ability to identify problems and turn them into opportunities. In the current landscape of climate change and increasing energy use, the demand for power modules that enable efficient and reliable conversion of electric power, in electric motors, for instance, is constantly rising. Improving the material system used in power modules, as well as their electrical and thermal interconnection, is critical to achieving this goal. Heraeus recognised this need and launched the Die Top System (DTS®), marking a revolutionary step in the assembly and connection technology of power modules. The system was developed in partnership with one of its prominent customers, Semikron Danfoss, an energy efficiency solutions provider, when they faced complications with their die top contact after using aluminium bonding wires.

Heraeus was faced with a complex task—achieving maximum power density with high reliability. Taking Semikron Danfoss’ idea and infusing it with its material expertise, the company created a system that matched their requirements. DTS® is custom-designed for the specific semiconductor layout and consists of a 50 μm thin copper foil with pre-applied sinter paste. The innovative system of sintered die to the substrate and copper foil to the top of the die and copper wires or ribbons are superior alternatives to traditional materials, like aluminium bonding wires and solder pastes.

The 30 per cent increase in module performance allows automotive manufacturers to achieve the same performance with smaller modules and less installation space, providing them with greater freedom of design.

Instances like these have cemented Heraeus’ position as a reliable partner in the power electronics space. As European company, it is also a staunch proponent of sustainability, determined to drive the change towards a carbon-neutral world. The electrification initiative in Europe is a key consideration in its business operations, and it takes every measure to reduce the dependence on fossil fuel energy generation.

With a commitment to reducing its carbon emissions by 42 per cent by 2030, it has pledged to the global mission of limiting global warming to 1.5 degrees Celsius. To achieve this, energy efficiency initiatives have been launched across its factories and photovoltaic systems were installed wherever possible. Furthermore, procurement of non-fossil-fuel and green electricity for operations is under investigation. To reduce the impact coming from raw materials, it strives to increase the content of recycled materials in its products wherever possible.

With a deep understanding of material combinations and the ability to test them in real-world scenarios, Heraeus is unleashing the true potential of power electronics. An illustrative track record of supplying high-performance products, especially material solutions for the automotive industry, continues to provide its customers with the confidence that they are working with the best.