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This paper presents the technologies incorporated in an electric vehicle (EV)/hybrid electric vehicle (HEV) inverter built with power semiconductors of silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFETs) instead of conventional silicon (Si) insulated gate bipolar transistors (IGBTs). A SiC inverter prototype of 2.9 L in size for driving an 80-kW motor was fabricated and evaluated on a motor test bench. The SiC inverter prototype attained average efficiency of 98.5% in the Worldwide harmonized Light-duty Test Cycle (WLTC) driving mode. The two main technologies achieved with this SiC inverter prototype are described. The first one is a new direct-cooled power module with a thick copper (Cu) heat spreader located under the semiconductors that improves thermal resistance by 34% compared with a conventional direct-cooled power module.

We have developed new P/M Al-Si wrought alloys having high strength and high wear resistance for use in the rotors and vanes of rotary car air conditioners. In addition, combined with the development of near-net-shape extrusion technologies, through a joint project with Diesel Kiki Co.,Ltd., we have succeeded in the world's first mass production of rotors made of P/M aluminum wrought alloy. In this paper, the properties and production technology of vanes and rotors made with new P/M Al-Si wrought alloys are presented.