New Power Module Could Transform Global Energy Systems

Scientists at the National Renewable Energy Laboratory have unveiled a new power module that could fundamentally change how the world converts and uses electricity. Called ULIS—short for Ultra-Low Inductance Smart power module—the device packs five times more power into a smaller package while wasting far less energy than existing technology. The breakthrough comes as global energy demand continues to climb, driven by data centers, electric vehicles, and manufacturing facilities hungry for reliable power.

The 1,200-volt, 400-amp module represents years of research aimed at solving a persistent problem in power electronics: energy loss during the conversion process. Every time electricity moves through a converter—whether in a data center, power plant, or electric vehicle—some energy dissipates as heat. ULIS dramatically reduces that waste.

Background

Power modules sit at the heart of modern electronics. They convert electricity from one form to another, acting as a bridge between power sources and the devices that use that power. Think of them like a transformer in a vehicle's electrical system—essential but often overlooked.

For decades, power modules have operated under the same basic design constraints. They use silicon carbide semiconductors housed in brick-like packages, with copper sheets bonded directly to ceramic bases. This approach works, but it has limits. The modules are bulky, generate significant heat, and waste energy through a phenomenon called parasitic inductance—essentially, resistance that builds up when electrical current changes direction.

As energy demands have grown, these limitations have become more pressing. Data centers now consume enormous amounts of electricity. Electric vehicles need efficient charging systems. Power grids struggle to handle fluctuating demand. The aviation industry is exploring electric aircraft that would require lightweight, reliable power systems. In all these cases, traditional power modules fall short.

Key Details

ULIS takes a fundamentally different approach to power module design. Instead of the traditional brick shape, researchers wound the circuits around a flat, octagonal disk. This unusual geometry allows more semiconductor devices to fit in a smaller space while enabling better current distribution.

The most striking improvement involves parasitic inductance. ULIS reduces this energy-wasting resistance by seven to nine times compared to existing silicon carbide modules. This means the module can switch electrical current faster and cleaner, with less voltage overshoot and ringing—the electrical noise that causes problems in sensitive equipment.

"We consider ULIS to be a true breakthrough. It's a future-proofed, ultrafast power module that will make the next generation of power converters more affordable, efficient, and compact." — Faisal Khan, NREL's chief power electronics researcher

The team also redesigned how the module handles heat. Instead of bonding copper to rigid ceramic, ULIS uses copper bonded to a flexible polymer called Temprion. This creates a thinner, lighter module that can be customized for different applications. The flexible design also allows the module to operate wirelessly, controlled and monitored without external cables. This modular, building-block approach means the same basic design can work in vastly different systems.

Efficiency Gains

The efficiency improvements are substantial. ULIS operates at 200 kilohertz—a much higher frequency than traditional modules—while maintaining the same energy loss that older modules produce at just 25 kilohertz. In practical terms, this means more of the electricity fed into the system actually reaches the end user instead of dissipating as waste heat.

The module can also monitor its own health and predict when components might fail. For applications where reliability is critical—aircraft flying at 30,000 feet or military vehicles in combat zones—this self-monitoring capability could be the difference between success and catastrophe.

What This Means

The applications for ULIS span nearly every sector of the modern economy. Data centers, which consume roughly 3 percent of global electricity and are growing rapidly due to artificial intelligence, could dramatically reduce their energy bills and cooling costs. Power grids could distribute electricity more efficiently, reducing losses that currently waste significant amounts of energy between generation and consumption.

The aviation industry is particularly interested. Electric aircraft are on the horizon, and they will need lightweight, efficient power systems. ULIS fits that requirement perfectly. Similarly, the military sees potential for advanced vehicles that need reliable, compact power electronics.

Energy companies exploring fusion reactors and microgrids could use ULIS to build smaller, more efficient systems. The module could even enable portable, ultra-fast electric vehicle chargers that operate at unprecedented speeds.

The broader implication is straightforward: as the world electrifies and energy demands grow, every percentage point of efficiency matters. ULIS doesn't solve the energy crisis on its own, but it removes a significant bottleneck in how we convert and distribute power. By squeezing more usable electricity from existing supplies, the technology addresses one piece of a much larger puzzle.

NREL has made ULIS available for licensing, meaning companies can begin integrating the technology into their products. The research team built the entire module in-house at the laboratory, and the wireless monitoring system has a patent pending. The breakthrough demonstrates how focused engineering research can deliver practical solutions to real-world problems—in this case, helping the world use energy more efficiently at a time when demand shows no signs of slowing.