The Enhanced Reliability of the Double Sided Cooled Package with Integrated Internal Isolation

Abstract:
Worldwide hybrid and electrical vehicle market is currently booming leading to the most exciting growth seen in Automotive for decades. As a result a wider spectrum of vehicles needs to be electrified. With the increase of the demand and the production, reliability of modules used in inverter is also expected to rise. Publication on Double Sided Cooled package, commonly called DSC, mainly focus on performance through higher power density, scalability and space advantages, but rarely on reliability where indeed they are introducing major improvements. DSC structure with integrated internal isolation is proposed as an optimum design of the DSC package. In this paper, it is introduced how the enhanced reliability is achieved and with, at the same time, improved thermal performance. Indeed, the interconnection between two exposed surfaces has crucial influence on the performance and reliability of the package. More precisely the homogeneity of the additive materials (E.g. mold compound, interconnection) should be carefully considered, as well as the coefficient of thermal expansion of the different materials. DSC with internal isolation fully addresses this key parameter. It is verified through Power cycling reliability test which are presented and where DSC can reach more than 100.000 cycles. Finally we discuss on the prospect in the future application using this kind of DSC Package.