Concepts for realizing High-Voltage Power Modules by Embedding of SiC Semiconductors

Today's power electronics modules typically consist of a ceramics substrate (DBC - Direct Bond Copper), carrying IGBTs, diodes or MOSFETs. These semiconductors are soldered or sintered to the ceramics and their top sides are interconnected by thick Al wires. An integration of further components or functions on the DBC substrate is difficult or even not possible. Therefore, driver circuits and controllers have to be mounted to a separate substrate, typically an organic Printed Circuit board (PCB). The PCB has to be connected to the DBC by wires or pins. The mechanical integration of the whole system requires a bulky housing. Embedding of power semiconductors like SiC MOSFET allows a significant size reduction, improved electrical performance and a high degree of reliability of such modules. In the last years, the capability of PCB embedding technology for the realization of low and high voltage power modules was demonstrated. Fraunhofer IZM together with partners from the industry demonstrated the feasibility for different applications, from single die SiC packages to high voltage automotive traction inverters. In this paper, a general overview about innovative power module technologies will be given and the embedding of power semiconductors will be introduced in detail. It will address all most relevant point, like the demands on the semiconductor, the thermal and electrical considerations as well as the demands on the used materials. To address the integration of the required driver circuits and controllers, the idea of modularization such electronics systems will also be presented. Here already packaged components will be used and embedded into PCB layers too. As a result, a modular approach to form a complete system will be developed. Different functional layers, e.g. power switches, logic modules, will be formed and finally stacked und connected to form the system. The concept and first realized demonstrators will be discussed.