Si IGBT phase-leg module packaging and cooling design for operation at 200 °C in hybrid electrical vehicle applications

A Si IGBT phase-leg module is designed and fabricated for operating at 200 °C in hybrid electrical vehicle (HEV) applications. First, a phase-leg package design is given including die selection, material selection, and layout design. Then the static and switching characterization of the fabricated module is conducted at various temperatures. The losses for a kW phase-leg in three-phase motor drive are calculated based on the characterization. Thermal performance of the proposed package and cooling is then evaluated with both (finite element analysis) FEA simulation and experiments. The simulation and experimental results agree well, which show that the proposed packaging design and cooling approach can maintain the Si IGBT junction temperature below 200 °C with 105 °C coolant. Finally, a buck converter composed of the phase-leg module is operated successfully with the device junction temperature heated up to 200 °C, which demonstrates the high temperature operation ability of the designed package module.