Low thermal resistance power module assembly
First Claim
1. A power module assembly with low thermal resistance, comprising:
- a heat sink plate with a lower surface and an upper surface, the heat sink plate comprising a plurality of passageways for coolant extending from the lower surface to the upper surface;
a circuit substrate positioned on the heat sink plate covering the coolant passageways, wherein the circuit substrate comprises a bonding layer extending about the periphery of each of the coolant passageways and comprising a material nonporous to the coolant; and
a set of power modules mounted on the circuit substrate opposite the bonding layer, each of the power modules being positioned on the circuit substrate over only one of the coolant passageways, wherein coolant flowing separately into each of the coolant passageways of the heat sink plate directly contacts the circuit substrate in an area opposite and proximate to each one of the power modules.
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Accused Products
Abstract
A power module assembly with low thermal resistance and enhanced heat dissipation to a cooling medium. The assembly includes a heat sink or spreader plate with passageways or openings for coolant that extend through the plate from a lower surface to an upper surface. A circuit substrate is provided and positioned on the spreader plate to cover the coolant passageways. The circuit substrate includes a bonding layer configured to extend about the periphery of each of the coolant passageways and is made up of a substantially nonporous material. The bonding layer may be solder material which bonds to the upper surface of the plate to provide a continuous seal around the upper edge of each opening in the plate. The assembly includes power modules mounted on the circuit substrate on a surface opposite the bonding layer. The power modules are positioned over or proximal to the coolant passageways.
62 Citations
20 Claims
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1. A power module assembly with low thermal resistance, comprising:
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a heat sink plate with a lower surface and an upper surface, the heat sink plate comprising a plurality of passageways for coolant extending from the lower surface to the upper surface; a circuit substrate positioned on the heat sink plate covering the coolant passageways, wherein the circuit substrate comprises a bonding layer extending about the periphery of each of the coolant passageways and comprising a material nonporous to the coolant; and a set of power modules mounted on the circuit substrate opposite the bonding layer, each of the power modules being positioned on the circuit substrate over only one of the coolant passageways, wherein coolant flowing separately into each of the coolant passageways of the heat sink plate directly contacts the circuit substrate in an area opposite and proximate to each one of the power modules. - View Dependent Claims (2, 3, 4, 5, 6)
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7. An electronic assembly with low thermal resistance, comprising:
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a metallic spreader plate with a lower surface and an upper surface and a heat dissipation opening extending through the plate from the upper surface to the lower surface; a circuit substrate; a bonding and sealing layer disposed between the circuit substrate and the plate and bonding the circuit substrate to the upper surface of the plate; and an electric component layer positioned on the circuit substrate distal to the plate comprising an integrated circuit (IC) generating heat during operation, the heat dissipating at least in part through the circuit substrate to a cooling medium in the heat dissipation opening, wherein the bonding and sealing layer blocks flow of the cooling medium between the circuit substrate and the plate; wherein the heat dissipation opening has a circular cross section with a diameter at the upper surface that is lower than a diameter at the lower surface; and wherein the heat dissipation opening comprises a side wall with a plurality of channels extending from the lower surface to the upper surface of the plate. - View Dependent Claims (8, 9, 10, 11)
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12. A method of manufacturing a power module assembly with low thermal resistance, comprising:
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providing a power module substrate comprising a plurality of power modules distributed in a pattern on a circuit substrate, the circuit substrate comprising a pair of electrical conductor layers with a ceramic isolation layer there between; providing a metallic plate having a thickness; based on the power module pattern, making a hole through the thickness of the plate for each of the power modules, wherein one of the holes is provided to extend through the plate to a particular one of the power modules to provide a path for coolant flowing on a first side of the plate flow to each of the power modules through the plate thickness; applying a bonding material to an upper surface of the plate, wherein the bonding material is applied continuously about the periphery of each of the holes in the plate; and bonding the plate to the power module substrate, wherein the holes in the plate are substantially aligned with the power modules with a central axis of the holes substantially aligned with a center of one of the power modules and wherein one of the electrical conductor layers mates with the bonding material. - View Dependent Claims (13, 14, 15, 16, 17, 18)
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19. A method of manufacturing an electronic assembly with low thermal resistance, comprising:
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providing a plurality of heat-generating electronic components distributed in a pattern on a circuit substrate, the circuit substrate comprising a pair of electrical conductor layers with an isolation layer there between; providing a metallic plate having a thickness; based on the power module pattern, making a hole through the thickness of the plate for each of the electronic components, wherein the holes are tapered to increase in size with distance from the circuit substrate; and bonding the plate to the circuit substrate, wherein the holes in the plate are substantially aligned with the electronic components with a central axis of the holes substantially aligned with a center of one of the electronic components.
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20. A power module assembly with low thermal resistance, comprising:
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a heat sink plate with a lower surface and an upper surface, the heat sink plate comprising a plurality of passageways for coolant extending from the lower surface to the upper surface; a circuit substrate positioned on the heat sink plate covering the coolant passageways, wherein the circuit substrate comprises a bonding layer extending about the periphery of each of the coolant passageways and comprising a material nonporous to the coolant; and a set of power modules mounted on the circuit substrate opposite the bonding layer, each of the power modules being positioned on the circuit substrate proximal to one of the coolant passageways; wherein each of the coolant passageways has a circular cross section with a sidewall extending from the lower surface to the upper surface of the heat sink plate and wherein the sidewalls slope inward from the lower surface such that each of the coolant passageways has a diameter at the lower surface that is greater than a diameter at the upper surface of the heat sink plate.
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Specification