SBIR Phase I: PowERazor: an Innovative Electronic Packaging Technology for Manufacturing High-reliability, High-density Power Electronics Modules

这一小型企业创新研究(SBIR)第一阶段项目旨在展示用于制造电力电子模块的电子封装技术的可行性，电力电子模块对于混合动力汽车或电动汽车、可再生能源发电机和电网等各种系统中的电能处理至关重要。电力半导体器件和基板技术的最新进展要求封装方案能够优化每个组件的性能，以进一步提高可靠性、密度和高温性能。满足这一需求的最佳途径是探索以前一直是使用焊接技术制造的障碍的三维封装体系结构。该项目将建立在用于设备互连的纳米材料技术的商业化成功的基础上，开发和实施一种创新的三维封装体系结构，该体系结构可以从两侧强制冷却得同样好。这种纳米材料已经在导热和导电性方面有了显著的提高，众所周知，它为设备互联提供了高可靠性和高温连接。此外，可以定制工艺要求，以显著简化使用现有焊料和环氧树脂连接方案难以创建的体系结构的制造。利用纳米材料芯片附件的加工优势，具体的技术目标是：(1)开发利用纳米材料制造平面功率模块的可制造工艺；(2)在施加持续电流的情况下测试模块；以及(3)在温度/功率循环测试下评估模块的可靠性，以及(4)故障机制的表征。由纳米材料实现的双面冷却平面功率模块技术将导致一个在市场上具有很强竞争力的产品。该项目的更广泛的影响/商业潜力将增强美国？电力电子领域的制造基地。电力电子模块是电能转换的中央处理单元，关系到国家经济和安全S。能源应用，特别是那些不依赖石油的能源应用，需要更高效的电力转换，以及对国家可靠性和可持续性的需求？S电力基础设施需要越来越多的电力转换。目前，电力电子模块市场由欧洲和亚洲制造的产品主导。该项目开发的技术的成功商业化将为不断增长的电力电子市场带来一家具有竞争力的美国电力模块制造商。这一成功将进一步加强根据NSF STTR计划开发的纳米材料产品的商业化努力，并直接转化为弗吉尼亚州西南部的经济增长。该项目的成功还将成为一个很好的教育和商业模式，将在国家科学基金会S的支持下开发的基础知识转化为商业世界。它将为学生提供一个理想的案例研究，以体验他们的研究活动的技术和经济影响。

This Small Business Innovative Research (SBIR) Phase I project is aimed at demonstrating the feasibility of an electronic packaging technology for manufacturing power electronics modules that are critical for electrical energy processing in a wide range of systems, such as hybrid or electric vehicles, renewable energy generators, and the power grid. Recent advances in power semiconductor devices and substrate technology require packaging schemes which optimize the performance of each component for further increases in reliability, density, and high-temperature performance. The best route for meeting this need is to explore three dimensional package architectures which have previously been a barrier for manufacturing using solder techniques. This project will build on the commercialization success of a nanomaterial technology for device interconnection, to develop and implement an innovative three dimensional package architecture which can be force cooled equally well from both sides. The nanomaterial, which already boasts significant increases in thermal and electrical conductivity, is known to provide high reliability and high temperature joints for device interconnection. In addition, processing requirements can be tailored to significantly simplify fabrication of architectures which are difficult to create using existing solder and epoxy connection schemes. Utilizing the processing benefits of the nanomaterial die attachment, the specific technical objectives are: (1) development of a manufacturable process with the nanomaterial for fabricating the planar power modules; (2) testing of the modules under applied continuous current; and (3) evaluation of the module reliability under temperature/power cycling tests and (4) characterization of failure mechanisms. The double-side cooled planar power module technology enabled by the nanomaterial would lead to a highly competitive product in the market place.The broader impact/commercial potential of this project would strengthen United States? manufacturing base in the field of power electronics. Power electronics modules are the central processing units for electrical energy conversion and are crucial to the nation?s economy and security. Energy applications, specifically those that provide independence from petroleum, require more efficient conversion of electrical power, and demand for reliability and sustainability of the nation?s power infrastructure requires an increasingly greater number of electrical conversions. Currently, the market of power electronics modules is dominated by products made in Europe and Asia. Successful commercialization of the technology developed in this project would usher in a competitive US manufacturer of power modules to the growing power electronics market. The success would further strengthen commercialization effort of the nanomaterial product developed under a NSF STTR program and directly translate to economic growth for Southwest Virginia. Success of this program would also serve as a good educational and business model for transferring fundamental knowledge developed under NSF?s support into the commercial world. It would present students an ideal case study to experience technological and economical impacts of their research activities.