U.S. patent application number 17/036096 was filed with the patent office on 2022-03-31 for power electronic modules including one or more layers including a polymer produced via a frontal ring-opening polymerization process.
This patent application is currently assigned to Toyota Motor Engineering & Manufacturing North America, Inc.. The applicant listed for this patent is Toyota Motor Engineering & Manufacturing North America, Inc.. Invention is credited to Shailesh N. Joshi.
Application Number | 20220102241 17/036096 |
Document ID | / |
Family ID | 1000005163517 |
Filed Date | 2022-03-31 |
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United States Patent
Application |
20220102241 |
Kind Code |
A1 |
Joshi; Shailesh N. |
March 31, 2022 |
POWER ELECTRONIC MODULES INCLUDING ONE OR MORE LAYERS INCLUDING A
POLYMER PRODUCED VIA A FRONTAL RING-OPENING POLYMERIZATION
PROCESS
Abstract
In one or more embodiments of the present disclosure, a power
electronic module may be described. The power electronic module may
comprise a power semiconductor device, a substrate coupled to the
power semiconductor device, and a base plate coupled to the
substrate. The substrate may include from 50 weight percent (wt. %)
to 99.9 wt. % of a poly(dicyclopentadiene) polymer. In one or more
other embodiments of the present disclosure, a method for
manufacturing a power electronic module may be described. The
method may include disposing a solution on a base plate. The
solution may include dicyclopentadiene monomer, a ruthenium-based
catalyst, and a trialkyl phosphite initiator. The method may
further include initiating a polymerization front within the
solution to produce a substrate formed directly on the base plate.
Furthermore, the method may include coupling a power semiconductor
device on the substrate to produce the power electronic module.
Inventors: |
Joshi; Shailesh N.; (Ann
Arbor, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Toyota Motor Engineering & Manufacturing North America,
Inc. |
Plano |
TX |
US |
|
|
Assignee: |
Toyota Motor Engineering &
Manufacturing North America, Inc.
Plano
TX
|
Family ID: |
1000005163517 |
Appl. No.: |
17/036096 |
Filed: |
September 29, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 21/4871 20130101;
H01L 23/3737 20130101; H01L 24/48 20130101; H01L 24/83 20130101;
H01L 24/29 20130101 |
International
Class: |
H01L 23/373 20060101
H01L023/373; H01L 21/48 20060101 H01L021/48 |
Claims
1. A power electronic module comprising: a power semiconductor
device; a substrate coupled to the power semiconductor device,
wherein the substrate comprises from 50 weight percent (wt. %) to
99.9 wt. % of a poly(dicyclopentadiene) polymer; and a base plate
coupled to the substrate.
2. The power electronic module of claim 1, wherein the power
semiconductor device comprises an insulated gate bipolar transistor
(IGBT), a reverse conducting insulated gate bipolar transistor
(RC-IGBT), a metal-oxide-semiconductor field-effect transistor
(MOSFET), a power metal-oxide-semiconductor field-effect transistor
(MOSFET), a diode, a power diode, a transistor, a power bipolar
transistor, or combinations thereof.
3. The power electronic module of claim 1, wherein the power
semiconductor device comprises silicon carbide (SiC), silicon
dioxide (SiO.sub.2), aluminum nitride (AlN), gallium nitride (GaN),
boron nitride (BN), or combinations thereof.
4. The power electronic module of claim 1, wherein the
poly(dicyclopentadiene) polymer is a homopolymer.
5. The power electronic module of claim 1, wherein the
poly(dicyclopentadiene) polymer is an interpolymer.
6. The power electronic module of claim 1, wherein the
poly(dicyclopentadiene) polymer has a dielectric strength of from
5.0 kilovolts per micron (kV/.mu.m) to 15 kV/.mu.m.
7. The power electronic module of claim 1, wherein the
poly(dicyclopentadiene) polymer has a Young's modulus of from 5.0
gigapascals (GPa) to 15 GPa.
8. The power electronic module of claim 1, wherein the
poly(dicyclopentadiene) polymer has a coefficient of thermal
expansion (CTE) of from 5.0 part per million per degrees Celsius
(ppm/.degree. C.) to 10 ppm/.degree. C.
9. The power electronic module of claim 1, wherein the substrate is
formed directly on the base plate.
10. The power electronic module of claim 1, wherein the substrate
further comprises one or more additives or fillers in an amount of
from 0.1 wt. % to 10 wt. %.
11. A method for manufacturing a power electronic module, the
method comprising: disposing a solution on a base plate, the
solution comprising dicyclopentadiene monomer, a ruthenium-based
catalyst, and a trialkyl phosphite initiator; initiating a
polymerization front within the solution to produce a substrate
formed directly on the base plate; and coupling a power
semiconductor device on the substrate to produce the power
electronic module.
12. The method of claim 11, wherein the polymerization front is
initiated by a thermal frontal polymerization (TFP) method, a
photofrontal polymerization method, or an isothermal frontal
polymerization (IFP) method.
13. The method of claim 11, further comprising electroplating a
coupling layer onto the surface of the substrate.
14. The method of claim 13, wherein the power semiconductor device
is coupled to the coupling layer via a layer of solder.
15. The method of claim 11, wherein the substrate comprises from 50
wt. % to 99.9 wt. % of a poly(dicyclopentadiene) polymer.
16. The method of claim 11, wherein the power semiconductor device
comprises an insulated gate bipolar transistor (IGBT), a reverse
conducting insulated gate bipolar transistor (RC-IGBT), a
metal-oxide-semiconductor field-effect transistor (MOSFET), a power
metal-oxide-semiconductor field-effect transistor (MOSFET), a
diode, a power diode, a transistor, a power bipolar transistor, or
combinations thereof.
17. The method of claim 11, wherein the power semiconductor device
comprises silicon carbide (SiC), silicon dioxide (SiO.sub.2),
aluminum nitride (AlN), gallium nitride (GaN), boron nitride (BN),
or combinations thereof.
18. The method of claim 11, wherein the poly(dicyclopentadiene)
polymer has a dielectric strength of from 5.0 kilovolts per micron
(kV/.mu.m) to 15 kV/.mu.m.
19. The method of claim 11, wherein the poly(dicyclopentadiene)
polymer has a Young's modulus of from 5.0 gigapascals (GPa) to 15
GPa.
20. The method of claim 11, wherein the poly(dicyclopentadiene)
polymer has a coefficient of thermal expansion (CTE) of from 5.0
part per million per degrees Celsius (ppm/.degree. C.) to 10
ppm/.degree. C.
Description
TECHNICAL FIELD
[0001] The present specification generally relates to improved
power electronics modules, and more specifically to power
electronic modules that include a substrate that include a polymer
produced via a frontal ring-opening polymerization (FROMP)
method.
BACKGROUND
[0002] Currently, a heat generating device, such as a power
semiconductor device, is coupled to a substrate, such as a direct
bonded copper (DBC) substrate, which are in turn coupled to a base
plate to remove heat and reduce the maximum operating temperature
of the heat generating device. Generally, each of these components
are coupled together using a bonding layer of, such as a solder
layer. As a result, a minimum of five to seven layers are typically
used for the effective operation of the heat generating device,
which limits the minimum achievable size of the heat generating
device assembly. Moreover, these layers do not create an effective
thermal path. That is, due to the numerous layers, a significant
thermal resistance exists between the heat generating device and
the base plate, which limits the amount by which the maximum
operating temperature of the heat generating device may be
reduced.
SUMMARY
[0003] Accordingly, there is an ongoing need for power electronic
modules that reduce the number of layers required for efficient
coupling of the components and removal of heat from the power
semiconductor devices of the power electronic modules. This may be
accomplished by the embodiments of the present disclosure. In
particular, the embodiments of the present disclosure use a polymer
formed from a frontal ring-opening polymerization (FROMP) method.
This polymer may have the properties and characteristics, such as
being an electric insulator while also having high thermal
conductivity. Moreover, the frontal ring-opening polymerization
(FROMP) method used to produce the polymer may allow for the
elimination of one or more layers from the power electronic module.
In particular, the frontal ring-opening polymerization (FROMP)
method allows for the substrate to be formed directly on the
surface of the base plate of the power electronic module,
eliminating the need for at least one layer of solder that is used
to couple conventional substrates to base plates. As a result, the
embodiments of the present disclosure may allow for the reduction
of the thermal resistance between the power semiconductor device
and the base plate, as well as a reducing in the overall size of
the power electronic module, by eliminating these one or more
layers.
[0004] In one or more embodiments of the present disclosure, a
power electronic module includes a power semiconductor device, a
substrate coupled to the power semiconductor device, and a base
plate coupled to the substrate. The substrate may include from 50
weight percent (wt. %) to 99.9 wt. % of a poly(dicyclopentadiene)
polymer.
[0005] In one or more other embodiments of the present disclosure,
a method for manufacturing a power electronic module includes
disposing a solution on a base plate. The solution may include
dicyclopentadiene monomer, a ruthenium-based catalyst, and a
trialkyl phosphite initiator. The method may further include
initiating a polymerization front within the solution to produce a
substrate formed directly on the base plate. Furthermore, the
method may include coupling a power semiconductor device on the
substrate to produce the power electronic module.
[0006] These and additional features provided by the embodiments
described herein will be more fully understood in view of the
following detailed description, in conjunction with the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The embodiments set forth in the drawings are illustrative
and exemplary in nature and not intended to limit the subject
matter defined by the claims. The following detailed description of
the illustrative embodiments can be understood when read in
conjunction with the following drawings, where like structure is
indicated with like reference numerals and in which:
[0008] FIG. 1 schematically depicts a cross-sectional view of an
example power electronic module including a power semiconductor
device coupled to a substrate that is coupled to a base plate,
according to embodiments of the present disclosure; and
[0009] FIG. 2 schematically depicts a cross-sectional view of an
example power electronic module including a power semiconductor
device coupled to a substrate that is coupled to a base plate,
according to conventional embodiments.
DETAILED DESCRIPTION
[0010] As noted hereinabove, embodiments of the present disclosure
are directed to power electronic modules that include one or more
layers including a polymer produced via a frontal ring-opening
polymerization (FROMP) method. As noted hereinabove, in
conventional power electronic modules, power semiconductor device
are typically coupled to a substrate, such as a direct bonded
copper (DBC) substrate, which are in turn coupled to a base plate
to remove heat and reduce the maximum operating temperature of the
heat generating device. Generally, each of these components are
coupled together using a bonding layer, such as a solder layer. As
a result, a minimum of five to seven layers are typically used for
the effective operation of the heat generating device, which limits
the minimum achievable size of the heat generating device.
Moreover, these layers do not create an effective thermal path.
That is, due to the numerous layers, a significant thermal
resistance exists between the heat generating device and the base
plate, which limits the amount by which the maximum operating
temperature of the heat generating device may be reduced.
[0011] In contrast, the embodiments eliminate one or more of these
layers which limit the operating conditions of the power electronic
module. In particular, the embodiments of the present disclosure
use a polymer formed from a frontal ring-opening polymerization
(FROMP) method. This polymer may have suitable properties and
characteristics, such as dielectric strength, coefficient of
thermal expansion, and Young's modulus, such that the polymer is an
electric insulator while also having high thermal conductivity.
Moreover, the frontal ring-opening polymerization (FROMP) method
used to produce the polymer may allow for the elimination of one or
more layers from the power electronic module. In particular, the
frontal ring-opening polymerization (FROMP) method allows for the
substrate to be formed directly on the surface of the base plate of
the power electronic module, eliminating the need for at least one
layer of solder that is used to couple conventional substrates to
base plates. As a result, the embodiments of the present disclosure
may allow for the reduction of the thermal resistance between the
power semiconductor device and the base plate, as well as a
reducing in the overall size of the power electronic module, by
eliminating these one or more layers.
[0012] Referring now to FIG. 1, a power electronics module 100
comprising a power semiconductor device 102 coupled to a substrate
104 that is coupled to a base plate 106 is schematically depicted.
In embodiments, the power semiconductor device 102 may include one
or more power semiconductor devices, such as, but not limited to,
an insulated gate bipolar transistor (IGBT), a reverse conducting
insulated gate bipolar transistor (RC-IGBT), a
metal-oxide-semiconductor field-effect transistor (MOSFET), a power
metal-oxide-semiconductor field-effect transistor (MOSFET), a
diode, a power diode, a transistor, a power bipolar transistor,
and/or combinations thereof. In embodiments, the power
semiconductor device 102 may be formed from any suitable material
such as, but not limited to, silicon carbide (SiC), silicon dioxide
(SiO.sub.2), aluminum nitride (AlN), gallium nitride (GaN), boron
nitride (BN), and combinations thereof.
[0013] As an example and not a limitation, the power semiconductor
device 102 may be included in the power electronic module 100 as a
component in an inverter and/or converter circuit used to
electrically power high load devices, such as electric motors in
electrified vehicles, such as, for example, hybrid vehicles,
plug-in hybrid electric vehicles, plug-in electric vehicles, and
the like. In such embodiments, the power semiconductor device 102
may operate at high current and/or high power, such as, for
example, power greater than or equal to 40 kilowatts (kW), greater
than or equal to 50 kW, greater than or equal to 60 kW, greater
than or equal to 70 kW, greater than or equal to 80 kW, greater
than or equal to 90 kW, greater than or equal to 100 kW, greater
than or equal to 110 kW, greater than or equal to 120 kW, greater
than or equal to 130 kW, greater than or equal to 140 kW, or
greater than or equal to 150 kW. Moreover, the power semiconductor
device 102 may operate under high temperatures, such as, for
example, temperatures greater than or equal to 100 degrees Celsius
(.degree. C.), greater than or equal to 125.degree. C., greater
than or equal to 150.degree. C., greater than or equal to
175.degree. C., greater than or equal to 200.degree. C., greater
than or equal to 225.degree. C., or greater than or equal to
250.degree. C. This may result in the power semiconductor device
102 generating significant amounts of heat. If this heat is not
removed from the power semiconductor device 102, the power
semiconductor device 102 may not be capable of continued operation
without failure.
[0014] As noted hereinabove, the heat may be removed from the power
semiconductor device 102 by coupling the power semiconductor device
102 to a substrate, such as the substrate 104, that is coupled to a
base plate, such as the base plate 106. Referring now to FIG. 2, a
conventional power electronics module 200 comprising a power
semiconductor device 102 coupled to a substrate 108 that is coupled
to a base plate 106 is schematically depicted. Conventional
substrates, such as the substrate 108, typically include an
insulating dielectric layer 110 disposed between two metal layers
112, 114. The insulating dielectric layer 110 may be formed from
alumina, aluminum nitride, silicon nitride, silicon carbide,
beryllium oxide, and/or combinations thereof, and the two metal
layers 112, 114 may be formed from copper, aluminum, gold, silver,
and/or combinations thereof. For example, the substrate 108 may be
a direct bonded copper (DBC) substrate or a direct bonded aluminum
(DBA) substrate.
[0015] As depicted in FIG. 2, a first layer of solder 116 may be
used to couple the power semiconductor device 102 to the substrate
108 and a second layer of solder 118 may be used to couple the
substrate 108 to the base plate 106. As noted hereinabove, the use
of a conventional substrate may necessarily limit the minimum size
of the power electronic module 200 due, at least in part, to the
number of layers of the substrate 108 as well as the additional
layers of the solder 116, 118 used to couple the power
semiconductor device 102, the substrate 108, and the base plate
106. Moreover, the use of a conventional substrate may necessarily
limit the amount by which the maximum operating temperature of the
power semiconductor device 102 may be reduced due, at least in
part, to the significant thermal resistance created by the number
of layers of the substrate 108 as well as the additional layers of
the solder 116, 118 used to couple the power semiconductor device
102, the substrate 108, and the base plate 106.
[0016] Referring again to FIG. 1, the power electronics module 100
may include a power semiconductor device 102 coupled to a substrate
104. In embodiments, the substrate 104 may include a
poly(dicyclopentadiene) (PDCPD) polymer. As used herein, the term
"polymer" may refer to polymeric compounds prepared by polymerizing
monomers, whether of the same or a different type. In some
embodiments, the poly(dicyclopentadiene) polymer may be a
homopolymer. As used herein, the term "homopolymer" may refer to a
polymer that is prepared by polymerizing only one monomer. In other
embodiments, the poly(dicyclopentadiene) polymer may be a
interpolymer. As used herein, the term "interpolymer" may refer to
a polymer that is prepared by polymerizing at least two monomers.
For example, the poly(dicyclopentadiene) polymer may be a polymeric
compound prepared by polymerizing dicyclopentadiene (DCPC) monomer
or the poly(dicyclopentadiene) polymer may be a polymeric compound
prepared by polymerizing dicyclopentadiene monomer at least one
additional comonomer.
[0017] The poly(dicyclopentadiene) polymer may have the dielectric,
thermal, and/or mechanical properties, such as dielectric strength,
coefficient of thermal expansion (CTE), and/or Young's modulus,
necessary to function as the substrate 104. That is, the
poly(dicyclopentadiene) polymer may be electrically insulating
while also being thermally conductive and providing the necessary
strength to support the power semiconductor device 102.
[0018] For example, in embodiments, the poly(dicyclopentadiene)
polymer may have a dielectric strength suitable for use as the
substrate 130 in the power electronic module 100. In embodiments,
the poly(dicyclopentadiene) polymer may have a dielectric strength
of from 5.0 kilovolts per micron (kV/.mu.m) to 15 kV/.mu.m, such as
from 5.0 kV/.mu.m to 13 kV/.mu.m, from 5.0 kV/.mu.m to 11 kV/.mu.m,
from 5.0 kV/.mu.m to 9.0 kV/.mu.m, from 5.0 kV/.mu.m to 7.0
kV/.mu.m, from 7.0 kV/.mu.m to 15 kV/.mu.m, from 7.0 kV/.mu.m to 13
kV/.mu.m, from 7.0 kV/.mu.m to 11 kV/.mu.m, from 7.0 kV/.mu.m to
9.0 kV/.mu.m, from 9.0 kV/.mu.m to 15 kV/.mu.m, from 9.0 kV/.mu.m
to 13 kV/.mu.m, from 9.0 kV/.mu.m to 11 kV/.mu.m, from 11 kV/.mu.m
to 15 kV/.mu.m, from 11 kV/.mu.m to 13 kV/.mu.m, or from 13
kV/.mu.m to 15 kV/.mu.m.
[0019] In embodiments, the poly(dicyclopentadiene) polymer may have
a Young's modulus suitable for use as the substrate 130 in the
power electronic module 100. For example, the
poly(dicyclopentadiene) polymer may have a Young's modulus of from
5.0 gigapascals (GPa) to 15 GPa, such as from 5.0 GPa to 13 GPa,
from 5.0 GPa to 11 GPa, from 5.0 GPa to 9.0 GPa, from 5.0 GPa to
7.0 GPa, from 7.0 GPa to 15 GPa, from 7.0 GPa to 13 GPa, from 7.0
GPa to 11 GPa, from 7.0 GPa to 9.0 GPa, from 9.0 GPa to 15 GPa,
from 9.0 GPa to 13 GPa, from 9.0 GPa to 11 GPa, from 11 GPa to 15
GPa, from 11 GPa to 13 GPa, or from 13 GPa to 15 GPa.
[0020] In embodiments, the poly(dicyclopentadiene) polymer may have
a coefficient of thermal expansion (CTE) suitable for use as the
substrate 130 in the power electronic module 100. For example, the
poly(dicyclopentadiene) polymer may have a coefficient of thermal
expansion (CTE) of from 5.0 part per million per degrees Celsius
(ppm/.degree. C.) to 10 ppm/.degree. C., such as from 5.0
ppm/.degree. C. to 9.0 ppm/.degree. C., from 5.0 ppm/.degree. C. to
8.0 ppm/.degree. C., from 5.0 ppm/.degree. C. to 7.0 ppm/.degree.
C., from 5.0 ppm/.degree. C. to 6.0 ppm/.degree. C., from 6.0
ppm/.degree. C. to 10 ppm/.degree. C., from 6.0 ppm/.degree. C. to
9.0 ppm/.degree. C., from 6.0 ppm/.degree. C. to 8.0 ppm/.degree.
C., from 6.0 ppm/.degree. C. to 7.0 ppm/.degree. C., from 7.0
ppm/.degree. C. to 10 ppm/.degree. C., from 7.0 ppm/.degree. C. to
9.0 ppm/.degree. C., from 7.0 ppm/.degree. C. to 8.0 ppm/.degree.
C., from 8.0 ppm/.degree. C. to 10 ppm/.degree. C., from 8.0
ppm/.degree. C. to 9.0 ppm/.degree. C., or from 9.0 ppm/.degree. C.
to 10 ppm/.degree. C.
[0021] As noted hereinabove, the poly(dicyclopentadiene) polymer
may be prepared by the polymerization of dicyclopentadiene monomer
and, optionally, one or more additional monomers. In particular,
the poly(dicyclopentadiene) polymer may be prepared by the frontal
ring-opening metathesis polymerization (FROMP) of dicyclopentadiene
monomer and, optionally, one or more additional monomers. Frontal
ring-opening metathesis polymerization is characterized in that the
polymerization front self-propagates through the monomer in a
uniform direction, such as from the top of the vessel the monomer
is placed in to the bottom of the vessel. Moreover, frontal
ring-opening metathesis polymerization is characterized in that the
polymerization process has a relatively mild operating conditions,
such as low initiation temperatures and pressures.
[0022] The poly(dicyclopentadiene) polymer may be prepared by any
known frontal ring-opening metathesis polymerization method known
in the art. For example, in embodiments, a solution including the
dicyclopentadiene monomer, a catalyst, and an initiator may be
prepared. The solution may be poured or deposited wherever the
substrate 104 is desired, such as on the base plate 106, and a
polymerization front may be initiated to form the
poly(dicyclopentadiene) polymer. In embodiments, the
poly(dicyclopentadiene) polymer may be prepared by a thermal
frontal polymerization (TFP) method, which uses an external energy
source to initiate the polymerization front, a photofrontal
polymerization method, which uses an external ultraviolet (UV)
source to initiate the polymerization front, or an isothermal
frontal polymerization (IFP) method, which uses the
Norrish-Trommsdorff, or gel effect, that occurs when monomer and
initiator diffuse into a polymer seed to initiate the
polymerization front.
[0023] The catalyst used to initiate the polymerization front may
be any suitable catalyst known in the art. For example, in
embodiments, the catalyst may be a ruthenium-based catalyst, such
as a ruthenium-benzylidene or ruthenium-indenylidine Grubbs-type
complex. The initiator may be any suitable initiator known in the
art that is compatible with the selected catalyst. For example, in
embodiments wherein the catalyst is a ruthenium-benzylidene or
ruthenium-indenylidine Grubbs-type complex, the initiator may be a
trialkyl phosphite (P(OR).sub.3). An example frontal ring-opening
metathesis polymerization of a dicyclopentadiene using a
ruthenium-based catalyst and a trialkyl phosphite initiator is
provided by Formula I:
##STR00001##
[0024] In embodiments, the poly(dicyclopentadiene) polymer may
include one or more fillers and/or additives. The additives may be
added to the poly(dicyclopentadiene) polymer in order to alter one
or more properties of the poly(dicyclopentadiene) polymer and, as a
result, the substrate 104. The one or more fillers and/or additives
may be incorporated into the poly(dicyclopentadiene) polymer by
mixing the additives directly with the monomer solution prior to
the initiation of the polymerization front. For example, in
embodiments, one or more ceramic particles, such as silicon carbide
(SiC), boron nitride (BN), silicon nitride (Si.sub.3N.sub.4), or
combinations of these, may be included in the
poly(dicyclopentadiene) polymer. The ceramic particles, which are
typically electrically insulating and/or thermally conductive, may
improve the dielectric strength and/or the thermal conductivity of
the poly(dicyclopentadiene) polymer and, as a result, the substrate
104. While the material of the additives is not particularly
limited, it should be understood that materials that are conductive
and/or generally reduce the dielectric strength of the
poly(dicyclopentadiene) polymer should not be included as these
conductive materials may result in the short and failure of the
power semiconductor device 102. In embodiments, the fillers and/or
additive may also be added to the poly(dicyclopentadiene) polymer
in order to alter one or more mechanical properties of the
poly(dicyclopentadiene) polymer and, as a result, the substrate
104. For example, the addition of the additives to the
poly(dicyclopentadiene) polymer may improve the Young's modulus of
the poly(dicyclopentadiene) polymer, the coefficient of thermal
expansion (CTE) of the poly(dicyclopentadiene) polymer, or
combinations thereof.
[0025] In embodiments, the substrate 104 may include a
poly(dicyclopentadiene) polymer in an amount greater than or equal
to 50.0 weight percent (wt. %) based on the total weight of the
substrate 104. For example, the substrate 104 may include a
poly(dicyclopentadiene) polymer in an amount of from 50.0 wt. % to
99.9 wt. %, from 50.0 wt. % to 99.5 wt. %, from 50.0 wt. % to 99.0
wt. %, from 50.0 wt. % to 95.0 wt. %, from 50.0 wt. % to 90.0 wt.
%, from 50.0 wt. % to 80.0 wt. %, from 50.0 wt. % to 70.0 wt. %,
from 50.0 wt. % to 60.0 wt. %, from 60.0 wt. % to 99.9 wt. %, from
60.0 wt. % to 99.5 wt. %, from 60.0 wt. % to 99.0 wt. %, from 60.0
wt. % to 95.0 wt. %, from 60.0 wt. % to 90.0 wt. %, from 60.0 wt. %
to 80.0 wt. %, from 60.0 wt. % to 70.0 wt. %, from 70.0 wt. % to
99.9 wt. %, from 70.0 wt. % to 99.5 wt. %, from 70.0 wt. % to 99.0
wt. %, from 70.0 wt. % to 95.0 wt. %, from 70.0 wt. % to 90.0 wt.
%, from 70.0 wt. % to 80.0 wt. %, from 80.0 wt. % to 99.9 wt. %,
from 80.0 wt. % to 99.5 wt. %, from 80.0 wt. % to 99.0 wt. %, from
80.0 wt. % to 95.0 wt. %, from 80.0 wt. % to 90.0 wt. %, from 90.0
wt. % to 99.9 wt. %, from 90.0 wt. % to 99.5 wt. %, from 90.0 wt. %
to 99.0 wt. %, from 90.0 wt. % to 95.0 wt. %, from 95.0 wt. % to
99.9 wt. %, from 95.0 wt. % to 99.5 wt. %, from 95.0 wt. % to 99.0
wt. %, from 99.0 wt. % to 99.9 wt. %, from 99.0 wt. % to 99.5 wt.
%, or from 99.5 wt. % to 99.9 wt. % based on the total weight of
the substrate 104.
[0026] In embodiments, the substrate 104 may include the one or
more fillers and/or additives in an amount less than or equal to 10
weight percent (wt. %) based on the total weight of the substrate
104. For example, the substrate 104 may include the one or more
fillers and/or additives in an amount of from 0.0 wt. % to 10 wt.
%, from 0.0 wt. % to 5.0 wt. %, from 0.0 wt. % to 4.0 wt. %, from
0.0 wt. % to 3.0 wt. %, from 0.0 wt. % to 2.0 wt. %, from 0.0 wt. %
to 1.0 wt. %, from 0.0 wt. % to 0.5 wt. %, from 0.0 wt. % to 0.1
wt. %, from 0.1 wt. % to 10 wt. %, from 0.1 wt. % to 5.0 wt. %,
from 0.1 wt. % to 4.0 wt. %, from 0.1 wt. % to 3.0 wt. %, from 0.1
wt. % to 2.0 wt. %, from 0.1 wt. % to 1.0 wt. %, from 0.1 wt. % to
0.5 wt. %, from 0.5 wt. % to 10 wt. %, from 0.5 wt. % to 5.0 wt. %,
from 0.5 wt. % to 4.0 wt. %, from 0.5 wt. % to 3.0 wt. %, from 0.5
wt. % to 2.0 wt. %, from 0.5 wt. % to 1.0 wt. %, from 1.0 wt. % to
10 wt. %, from 1.0 wt. % to 5.0 wt. %, from 1.0 wt. % to 4.0 wt. %,
from 1.0 wt. % to 3.0 wt. %, from 1.0 wt. % to 2.0 wt. %, from 2.0
wt. % to 10 wt. %, from 2.0 wt. % to 5.0 wt. %, from 2.0 wt. % to
4.0 wt. %, from 2.0 wt. % to 3.0 wt. %, from 3.0 wt. % to 10 wt. %,
from 3.0 wt. % to 5.0 wt. %, from 3.0 wt. % to 4.0 wt. %, from 4.0
wt. % to 10 wt. %, from 4.0 wt. % to 5.0 wt. %, or from 5.0 wt. %
to 10 wt. % based on the total weight of the substrate 104.
[0027] Referring again to FIG. 1, the power semiconductor device
102 may be coupled to the substrate 104. In embodiments, the power
semiconductor device 102 may be coupled to the substrate 104 via a
layer of solder 116. In such embodiments, a electrically conductive
coupling layer (not shown) may be disposed across the surface of
the substrate 104 prior to coupling the power semiconductor device
102 to the substrate 104. The coupling layer may be deposited by
any method known in the art, such as by electroplating, sputtering,
or combinations of these. In other embodiments, the power
semiconductor device may be embedded directly into the substrate
104. This may be accomplished by submerging the power semiconductor
device 102 in the monomer solution prior to the initiation of the
polymerization front.
[0028] The substrate 104 may be coupled (e.g., bonded) to the base
plate 106. The base plate 106 may be a cooling apparatus, such as a
heat sink or cold plate, that is operable to remove heat from the
power semiconductor device 102 and the substrate 104. As noted
hereinabove, the substrate 104 may include a
poly(dicyclopentadiene) polymer that is prepared via a frontal
ring-opening polymerization method. As noted hereinabove, such
methods result in a uniform polymerization front that may be
imitated at relatively low temperatures and pressures. As such, in
embodiments, the substrate 104 may be coupled to the base plate 106
by forming the poly(dicyclopentadiene) polymer of the substrate 104
directly on the base plate 106. In such embodiments, for example, a
solution that includes the monomer, the catalyst, and the
initiator, as described in detail hereinabove, may be poured or
otherwise deposited directly onto the base plate 106. Once the
solution has been deposited on the base plate 106, the substrate
104 may be formed by initiating a polymerization front within the
solution as discussed in detail hereinabove.
[0029] Referring again to FIG. 2, as discussed hereinabove,
conventional substrates, such as the substrate 108, are bonded to
the base plate 106 via a solder layer. The frontal ring-opening
polymerization of the present disclosure may allow for such solder
layers to be eliminated as the substrate 104 may be formed directly
upon the base plate 106. This may improve the thermal conductivity
of the power electronic module 100 compared to conventional power
electronic modules, such as the power electronic module depicted in
FIG. 2. Moreover, the elimination of solder layer 118 may reduce
the minimum achievable size of the power electronic module 100
compared to conventional power electronic modules, such as the
power electronic module depicted in FIG. 2.
[0030] While the embodiments of the present disclosure, such as the
embodiment depicted in FIG. 1, is described as a power electronic
module including a single power semiconductor device coupled to a
single substrate, it should be understood that, in embodiments, the
power electronic module 100 may include two or more power
semiconductor devices coupled to one or more discrete
substrates.
[0031] Moreover, it should be understood that the
poly(dicyclopentadiene) polymer may have one or more applications
in electronic devices similar to the power electronic module 100 of
the present disclosure. For example, in alternative embodiments,
the poly(dicyclopentadiene) polymer may be used as an encapsulating
layer to cover one or more power electronic modules. That is, the
power electronic module 100, or even the power electronic module
200, may be encapsulated by the poly(dicyclopentadiene) polymer.
This may prevent and protect the power electronic modules from
abrasion or short caused by contact with an external element.
Conventional encapsulation methods require high temperature and/or
high pressure polymerization methods to achieve such an
encapsulation. However, as discussed in detail hereinabove, the
poly(dicyclopentadiene) polymer of the present disclosure may allow
the power electronic modules to be encapsulated by a frontal
ring-opening polymerization method that uses low temperatures and
low pressures.
[0032] It should now be understood that embodiments described
herein are directed to various configurations of a power electronic
module having an improved thermal conductivity and reduced size.
The power electronic module may generally include a power
semiconductor device coupled to a substrate coupled to a base
plate. The substrate may include a poly(dicyclopentadiene) polymer
produced via the frontal ring-opening polymerization of
dicyclopentadiene monomer. The frontal ring-opening polymerization
method used to produce the poly(dicyclopentadiene) polymer may
allow for the substrate to be formed directly on the base plate,
which effectively eliminates a layer that was formally necessary in
conventional power electronic modules. The removal of this layer,
which limited the thermal conductivity and size of conventional
power electronic modules, may in turn improve the thermal
conductivity of the power electronic module, improving the
operational temperatures of the power semiconductor device, and
reduce the minimum achievable size of the power electronic
module.
[0033] The terminology used herein is for the purpose of describing
particular aspects only and is not intended to be limiting. As used
herein, the singular forms "a," "an," and "the" are intended to
include the plural forms, including "at least one," unless the
content clearly indicates otherwise. "Or" means "and/or." As used
herein, the term "and/or" includes any and all combinations of one
or more of the associated listed items. It will be further
understood that the terms "comprises" and/or "comprising," or
"includes" and/or "including" when used in this specification,
specify the presence of stated features, regions, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, regions,
integers, steps, operations, elements, components, and/or groups
thereof. The term "or a combination thereof" means a combination
including at least one of the foregoing elements.
[0034] It is noted that the terms "substantially" and "about" may
be utilized herein to represent the inherent degree of uncertainty
that may be attributed to any quantitative comparison, value,
measurement, or other representation. These terms are also utilized
herein to represent the degree by which a quantitative
representation may vary from a stated reference without resulting
in a change in the basic function of the subject matter at
issue.
[0035] While particular embodiments have been illustrated and
described herein, it should be understood that various other
changes and modifications may be made without departing from the
spirit and scope of the claimed subject matter. Moreover, although
various aspects of the claimed subject matter have been described
herein, such aspects need not be utilized in combination. It is
therefore intended that the appended claims cover all such changes
and modifications that are within the scope of the claimed subject
matter.
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