Compact power module for integrated traction inverters with highest power density

In Hybrid and Electric Vehicle (xEV) traction inverters the ongoing trend for mating power electronic components with mechanical assemblies (i.e. in the powertrain with combustion engine or gear-box) must be supported by the development of compact and robust power modules offering highest power densities. This paper presents a new concept for a compact and direct liquid cooled power module for automotive traction applications. The power module is comprised of a newly developed high performance liquid cooling system that is combined with advanced sintering die attach and copper-wire-bonding technology being encapsulated in a transfer-molded package in order to live up to stringent requirements of automotive traction inverter designs to come. Prototypes of this module were manufactured and tested to confirm their electrical, thermal and lifetime characteristics and have proven their flexibility and performance.