Owing to their advantages in switching speed, temperature characteristics and voltage withstand capability, silicon carbide(SiC) power modules are gradually applied in the motor controllers of electric vehicles. As a core component of electric vehicles, the motor controller demands high electro-thermal characteristics of power modules, posing a significant challenge to SiC packaging. In this paper, the mainstream HybridPACK Drive module packaging is taken as an example, the driver and direct bonded copper(DBC) layout are optimized, and the copper wire bonding technology is introduced to balance the module's electro-thermal performance and reliability. In addition, the response surface methodology is used to optimize the elliptical Pin-Fin heat sink, thereby enhancing the module's heat dissipation performance. Finally, prototypes of SiC power modules before and after optimization were fabricated for comparison, and a double-pulse test setup and a power back-to-back test setup were established respectively to evaluate the electro-thermal performance of the two approaches. Experimental results indicate that when the chip spacing was equal to half the die width, the optimized power module can achieve a superior thermal performance while maintaining the electrical characteristics.
维普
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