A Double-Sided Cooled SiC MOSFET Power Module for EV Inverters

Double-sided cooled (DSC) power module structures enable high power density for motor drive inverters ideal for electric vehicles (EVs). This work presents a DSC power module using fast-switching 1200 V silicon carbide
mosfet
devices in a half-bridge topology, with heterogeneous integration of gate control circuitry and condition monitoring. This article describes the module's novel design and a top-down approach to it driven by a prototype inverter for EVs. Highlighted are the specific implementations of the module's key enabling technologies: 1) vertical device-top interconnects in the form of truncated rectangular pyramidal blocks made of copper, enabling maximum heat dissipation; 2) a low-temperature cofired ceramic interposer for high mechanical strength and improved electrical isolation; 3) built-in gate driver boards; 4) embedded temperature sensors. This article also details the module's unique fabrication process, highlighting its good yield and ease of fabrication. Finally, the prototype module is validated using double-pulse tests in a clamped inductive load at full load current and 800-V dc-link voltage.