PowerSynth-Guided Reliability Optimization of Multi-Chip Power Module

High-performance Multi-Chip Power Modules (MCPMs) are essential for high-density and efficient power conversion. Meanwhile, the chip layout and design methodology fundamentally determine thermal and reliability performance. Hign-density power modules typically consist of wide-bandgap (WBG) semiconductor die, soldering materials, baseplate, and heatsink packed on a single substrate. To a great extent, the reliability of power modules depends on these material electrothermal-mechanical properties during variable operating conditions. Appropriate thermal management can reduce stress and enhance the component lifetime by controlling junction temperature. In this work, a fast, generic, and scalable transient thermal model has been developed for the PowerSynth layout synthesis tool to optimize layer material, thickness, and layer stack configurations by minimizing thermal stress due to thermal cycling. This model has shown approximately 3,489 times speed up with less than 10% mismatch compared to ANSYS simulation. A PowerSynth-guided design-for-reliability computer-aided design (CAD) flow is presented to optimize both the layer stack and the layout simultaneously.