Power Embedding for the Electromobility of the Future

Assembly And Interconnection Technology Power Embedding for the Electromobility of the Future

2025-07-02 From Kristin Rinortner | Translated by AI 2 min Reading Time

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For the transformation to electromobility to succeed, the range and charging speeds of batteries must reach levels achievable only with high voltages and currents. However, higher electrical power quickly pushes conventional control technology to its limits. The power embedding technologies from AT&S sustainably solve this problem.

E-cars with a 620 miles range, charged in 10 minutes? With power embedding from AT&S, these figures become realistic.(Image: AT&S / Shutterstock [M]) — E-cars with a 620 miles range, charged in 10 minutes? With power embedding from AT&S, these figures become realistic.
(Image: AT&S / Shutterstock [M])

An electric car that is fully charged in ten minutes and then offers a range of 620 miles is no longer unrealistic. Modern batteries, fast-charging stations with corresponding power, and efficient power electronics have made electric cars increasingly competitive in terms of travel comfort in recent years. However, achieving further improvements in this area requires fundamental changes to power electronics.

"The alternating current from the grid is converted into direct current using inverters, which can then be stored in the batteries. The higher the electrical power the system can handle, the faster I can charge an electric car. However, this requires power electronics capable of managing high currents and voltages. Current inverters use semiconductor circuits connected with wire bonding technology, whose lifespan decreases as the required power increases further. We have developed solutions that enable automakers to realize the next generations of their fast-charging technologies," explains AT&S CTO Peter Griehsnig.

Lighter, More Durable, And Greener

The Austrian PCB specialist AT&S combines new semiconductor materials such as gallium nitride and silicon carbide with the assembly and interconnection technology known as "Power Embedding." This enables the production of switches for inverters that are smaller, more durable, and more efficient than existing models.

"Our embedded semiconductor chips can handle up to 1,500 V and up to 200 A. Inverters with our embedding technology require less space, save weight, and are flexible in design. As a result, many automakers are already showing interest and working with us on several EU research projects such as 'HiEfficient' and 'HiPower 5.0' on future developments," says Mike Morianz, Program Manager at AT&S.

Modules with semiconductors made from GaN and SiC are currently connected to the circuit board using wire bonding. In contrast, the Austrians achieve power embedding by embedding multiple semiconductor chips in parallel with microvia connections and sinter lamination according to specified designs. "This significantly increases efficiency and reliability. Losses are reduced, the solution takes up only half the space, and it lasts ten times more switching cycles compared to conventional technology," says Morianz.

Not only in electric cars are range and fast-charging technologies becoming increasingly important. In Scandinavia, battery-powered ferries are already being tested, which can be charged in just a few minutes during short docking times. In this area as well, the technology can help partners design the traffic and transport infrastructure of tomorrow to be more durable and sustainable. (kr)

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