Low-Cost Packaging of SiC Power Modules for EV Traction Inverters

The increasing demand for efficient and cost-effective power electronics in electric vehicle (EV) traction inverters necessitates innovative power module designs. This paper presents a novel SiC power module packaging focused on low-cost fabrication and assembly.. The proposed design features a simplified sandwich structure consisting of a lead frame, the innovative epoxy composite deposited on a high-performance cold plate. The novel epoxy composite eliminates the critical solder connection typically found between the DBC/AMB and the cold plate. This significantly streamlines the thermal path by reducing the number of material layers and interfaces between the SiC chip and the coolant. As a result, the integrated stack-up achieves significantly low junction-to-coolant thermal resistance (Rth) while delivering substantial cost savings related to power module module packaging. This work provides the details on the power module prototype fabrication steps and functionality including the electrical and thermal performance..