Effects of Encapsulant Properties on the Thermo-Mechanical Reliability of Double-Side Cooled Power Modules for Traction Inverters

Boshkovski, Filip; Nicholas, Carl; Zhang, Zichen; Paret, Paul; Ngo, Khai D. T.; Lu, Guo-Quan

doi:10.1109/ECCE53617.2023.10362816

Effects of Encapsulant Properties on the Thermo-Mechanical Reliability of Double-Side Cooled Power Modules for Traction Inverters

Conference · 28 December 2023

DOI:https://doi.org/10.1109/ECCE53617.2023.10362816· OSTI ID:2293500

Boshkovski, Filip; Nicholas, Carl; Zhang, Zichen; ; Ngo, Khai D. T.; Lu, Guo-Quan

Double-side cooled power modules are being developed for next-generation traction inverters due to their better heat extraction, lower profile, and lower parasitic inductances. However, due to their rigid structure, they cause reliability concerns arising from high thermo-mechanical stresses at the interconnection joints in the module. In this work, a materials-based approach using rigid encapsulants is presented for reducing thermo-mechanical fatigue. Finite-element thermo- mechanical simulations were performed to examine the effects of the elastic modulus and coefficient of thermal expansion of epoxy- based encapsulants on the bond deformation inside a double-side cooled power module. It was found that a rigid encapsulant with a high modulus of 6.0 GPa or above and a coefficient of thermal expansion around 20 ppm/oC would improve the thermo- mechanical reliability of double-side cooled power modules by decreasing the permanent bond deformation inside the modules by 50-60%.

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Research Organization:: National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office

DOE Contract Number:: AC36-08GO28308

OSTI ID:: 2293500

Report Number(s):: NREL/CP-5400-85196; MainId:85969; UUID:b8cacdda-bf5c-46c9-b51b-b2f6abbc83c5; MainAdminId:71777

Country of Publication:: United States

Language:: English

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