High performance cooling system for automotive inverters

A novel double-side cooled power module is presented which delivers superior cooling performance with the potential for improved robustness to thermal cycling. The semiconductor dies are sandwiched between conventional DBC substrates, the substrates being directly cooled rather than through a conventional heat spreader heat sink assembly. A theoretical analysis is presented illustrating that direct cooling can offer a lower total thermal resistance provided the heat transfer coefficient at the cooled surface is sufficiently high. Experimental results demonstrate the effectiveness of the selected impingement cooling technique when applied in both single- and double-side cooled formats. Measurements on the double-side cooled structure show a total thermal resistance (junction to ambient) that is less than 40% of the junction to case resistance of a conventional module. Similar improvements are observed in the transient thermal impedance (step response) curve indicating that thermal cycling ranges will be reduced under all operational conditions.