Jet-Dispensing-Based Assembly of Electric Field Adaptively Controlled Structure in Power Electronic Modules

In power modules, partial discharge (PD) at the triple points of “Copper-Ceramic-Silicone Gel” poses a significant challenge to the development of higher voltage and power density. This article utilized a reliable and controllable method, jet dispensing, to assemble the electric field adaptively controlled structure in power electronic modules to optimize the electric field distribution. The structure was composed of ZnO/epoxy resin nonlinear conductivity composites, with the thickness controlled at $300~\pm ~50~\mu $ m. The assembled electric field adaptively controlled structure significantly enhanced the PD inception voltage (PDIV) of the module from 6.0 to 13.2 kV, with a 120.0% increase under the sinusoidal waves, and from 4.0 to 9.6 kV under positive polarity square-wave pulses, with an increased ratio of 140.0%. This article provides a new perspective on the application of nonlinear materials in power electronic modules.