Article(id=1154049717152501892, tenantId=1146029695717560320, journalId=1146031654075715584, issueId=1154049103748125137, articleNumber=null, orderNo=null, doi=10.13234/j.issn.2095-2805.2024.3.87, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1706889600000, receivedDateStr=2024-02-03, revisedDate=1707840000000, revisedDateStr=2024-02-14, acceptedDate=1708617600000, acceptedDateStr=2024-02-23, onlineDate=1753076493776, onlineDateStr=2025-07-21, pubDate=1716998400000, pubDateStr=2024-05-30, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1753076493776, onlineIssueDateStr=2025-07-21, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1753076493776, creator=13701087609, updateTime=1753076493776, updator=13701087609, issue=Issue{id=1154049103748125137, tenantId=1146029695717560320, journalId=1146031654075715584, year='2024', volume='22', issue='3', pageStart='1', pageEnd='306', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1753076347529, creator=13701087609, updateTime=1753780989436, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1157004586184695853, tenantId=1146029695717560320, journalId=1146031654075715584, issueId=1154049103748125137, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1157004586184695854, tenantId=1146029695717560320, journalId=1146031654075715584, issueId=1154049103748125137, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=87, endPage=92, ext={EN=ArticleExt(id=1154049717693567126, articleId=1154049717152501892, tenantId=1146029695717560320, journalId=1146031654075715584, language=EN, title=3D Packaging for Low-inductance Bidirectional Switch of SiC Power Module, columnId=1154049691676303617, journalTitle=Journal of Power Supply, columnName=Packaging Design and Optimization, runingTitle=null, highlight=null, articleAbstract=

The bidirectional switch is extensively applied in the fields such as state-solid breakers and photovoltaic inverters, and increasing attention is paid to the bidirectional switch of SiC power modules owing to its low power loss and high switching frequency. However, due to the traditional packaging methods for Si power modules, the bidirectional switch of the SiC power module is challenged by the issue of high switching speed. Aimed at the low-inductance packaging requirement, a chip-on-chip 3D packaging method is proposed for the bidirectional switch of the SiC power module. The circuit topology and geometric structure of the 3D packaging are given, and the communication loop and parasitic inductance of the 3D packaging are analyzed. In addition, the process was designed for the 3D packaging, and a prototype of the bidirectional switch of the SiC power module was fabricated. Experimental results of a double-pulse test verified the feasibility and effectiveness of the proposed 3D packaging for the bidirectional switch of the SiC power module.

, correspAuthors=null, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, authorCompany=null, fund=null, authors=null, authorsList=Siyuan WANG, Yuxi LIANG, Peng SUN, Mingrui ZOU, Jiakun GONG, Zheng ZENG), CN=ArticleExt(id=1154049743014580579, articleId=1154049717152501892, tenantId=1146029695717560320, journalId=1146031654075715584, language=CN, title=基于3D封装的低感双向开关 SiC 功率模块研究, columnId=1154049691818909955, journalTitle=电源学报, columnName=封装设计与优化, runingTitle=null, highlight=null, articleAbstract=

双向开关在固态断路器、光伏逆变器等领域具有不可替代的作用,而低损耗、高开关频率的双向开关SiC功率模块得到了越来越多的关注。然而,现有双向开关SiC功率模块仍然沿用传统Si功率模块的封装方法,难以适应SiC器件的高速开关优势。针对双向开关SiC功率模块的低感封装需求,提出一种芯片堆叠的3D封装集成方法。给出了3D封装的电路拓扑和几何结构,分析3D封装的换流回路和寄生电感规律,设计3D封装的技术工艺,并研制了双向开关SiC功率模块样机。采用双脉冲测试的实验结果验证了所提3D封装双向开关SiC功率模块的可行性和有效性。

, correspAuthors=null, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=AUcDDfeF+PgvGGUlgKWKlQ==, magXml=bBJATm2/PFoS1Zkk8/WY7Q==, pdfUrl=null, pdf=Zy8sxFBNJsyXQ7Em9Ai7Og==, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=7P4EJMzep0ZZPFu1Vqlowg==, mapNumber=null, authorCompany=null, fund=null, authors=

王思媛(2002-),女,硕士研究生。研究方向:SiC 功率器件封装。E-mail: 1754818641@qq.com。

梁钰茜(1998-),女,中国电源学会学生会员,硕士研究生。研究方向:SiC 功率器件封装。E-mail:1181132344@qq.com。

孙鹏(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:sunpeng_96@163.com。

邹铭锐(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:zoumingrui@cqu.edu.cn。

龚佳坤(2000-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:gonjiakun@cqu.edu.cn。

曾正(1986-),男,中国电源学会会员,通信作者,博士,教授。研究方向:SiC 功率器件封装。E-mail: zengerzheng@126.com。

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王思媛(2002-),女,硕士研究生。研究方向:SiC 功率器件封装。E-mail: 1754818641@qq.com。

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王思媛(2002-),女,硕士研究生。研究方向:SiC 功率器件封装。E-mail: 1754818641@qq.com。

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梁钰茜(1998-),女,中国电源学会学生会员,硕士研究生。研究方向:SiC 功率器件封装。E-mail:1181132344@qq.com。

"}, bioImg=null, bioContent=

梁钰茜(1998-),女,中国电源学会学生会员,硕士研究生。研究方向:SiC 功率器件封装。E-mail:1181132344@qq.com。

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孙鹏(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:sunpeng_96@163.com。

"}, bioImg=null, bioContent=

孙鹏(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:sunpeng_96@163.com。

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邹铭锐(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:zoumingrui@cqu.edu.cn。

"}, bioImg=null, bioContent=

邹铭锐(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:zoumingrui@cqu.edu.cn。

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龚佳坤(2000-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:gonjiakun@cqu.edu.cn。

"}, bioImg=null, bioContent=

龚佳坤(2000-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:gonjiakun@cqu.edu.cn。

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曾正(1986-),男,中国电源学会会员,通信作者,博士,教授。研究方向:SiC 功率器件封装。E-mail: zengerzheng@126.com。

"}, bioImg=null, bioContent=

曾正(1986-),男,中国电源学会会员,通信作者,博士,教授。研究方向:SiC 功率器件封装。E-mail: zengerzheng@126.com。

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(in Chinese)., articleTitle=Packaging, Characterizition, and Integration of SiC Power Devices, refAbstract=null)], funds=[Fund(id=1154049747703812535, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, awardId=52177169, language=EN, fundingSource=National Natural Science Foundation of China(52177169), fundOrder=null, country=null), Fund(id=1154049747766727099, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, awardId=52177169, language=CN, fundingSource=国家自然科学基金资助项目(52177169), fundOrder=null, country=null)], companyList=[AuthorCompany(id=1154049743941521764, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, xref=1, ext=[AuthorCompanyExt(id=1154049743945716069, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, companyId=1154049743941521764, language=EN, country=null, province=null, city=null, postcode=null, 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articleId=1154049717152501892, language=EN, label=Fig. 2, caption=Circuit schematic and packaging configuration of bidirectional switch of SiC power module, figureFileSmall=UF4ihbP2MvqDW92K8hzWvA==, figureFileBig=YKF4OHhjGOwhR1mzrcyFUA==, tableContent=null), ArticleFig(id=1154049746755899808, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, language=CN, label=图2, caption=双向开关 $\mathrm{{SiC}}$ 功率模块的电路原理和封装结构, figureFileSmall=UF4ihbP2MvqDW92K8hzWvA==, figureFileBig=YKF4OHhjGOwhR1mzrcyFUA==, tableContent=null), ArticleFig(id=1154049746814620066, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, language=EN, label=Fig. 3, caption=Communication loop of bidirectional switch of SiC power module, figureFileSmall=tUWG52LOT+xjIMdIZ5V2NA==, figureFileBig=6+qLv9gNDOYuW66ndseEvQ==, tableContent=null), ArticleFig(id=1154049746877534628, tenantId=1146029695717560320, journalId=1146031654075715584, 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figureFileSmall=null, figureFileBig=null, tableContent=
寄生电感 功率端子 1 功率端子 2 中点端子
功率端子 1 1.88611 0.05274 $-{0.007}\;{11}$
功率端子 2 0.05274 1.89849 $-{0.007}\;{33}$
中点端子 $-{0.007}\;{11}$ $-{0.007}\;{33}$ 0.04711
), ArticleFig(id=1154049747464737198, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, language=CN, label=表1, caption=3D 封装双向开关 $\mathrm{{SiC}}$ 功率模块的寄生电感, figureFileSmall=null, figureFileBig=null, tableContent=
寄生电感 功率端子 1 功率端子 2 中点端子
功率端子 1 1.88611 0.05274 $-{0.007}\;{11}$
功率端子 2 0.05274 1.89849 $-{0.007}\;{33}$
中点端子 $-{0.007}\;{11}$ $-{0.007}\;{33}$ 0.04711
), ArticleFig(id=1154049747515068847, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, language=EN, label=Tab. 2, caption=Key parameters of double-pulse test, figureFileSmall=null, figureFileBig=null, tableContent=
参数 数值
负荷电感/μH 200
直流侧电容/μF 100
直流母线电压/V 300~600
负荷电流/A 20
), ArticleFig(id=1154049747569594800, tenantId=1146029695717560320, journalId=1146031654075715584, articleId=1154049717152501892, language=CN, label=表2, caption=双脉冲测试关键参数, figureFileSmall=null, figureFileBig=null, tableContent=
参数 数值
负荷电感/μH 200
直流侧电容/μF 100
直流母线电压/V 300~600
负荷电流/A 20
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基于3D封装的低感双向开关 SiC 功率模块研究
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王思媛 1 , 梁钰茜 2 , 孙鹏 2 , 邹铭锐 2 , 龚佳坤 2 , 曾正 2
电源学报 | 封装设计与优化 2024,22(3): 87-92
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电源学报 | 封装设计与优化 2024, 22(3): 87-92
基于3D封装的低感双向开关 SiC 功率模块研究
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王思媛1 , 梁钰茜2 , 孙鹏2 , 邹铭锐2 , 龚佳坤2 , 曾正2
作者信息
  • 1 重庆大学辛辛那提大学联合学院 重庆 400044
  • 2 重庆大学 电气工程学院 重庆 400044
  • 王思媛(2002-),女,硕士研究生。研究方向:SiC 功率器件封装。E-mail: 1754818641@qq.com。

    梁钰茜(1998-),女,中国电源学会学生会员,硕士研究生。研究方向:SiC 功率器件封装。E-mail:1181132344@qq.com。

    孙鹏(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:sunpeng_96@163.com。

    邹铭锐(1996-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:zoumingrui@cqu.edu.cn。

    龚佳坤(2000-),男,中国电源学会学生会员,博士研究生。研究方向:SiC 功率器件封装。E-mail:gonjiakun@cqu.edu.cn。

    曾正(1986-),男,中国电源学会会员,通信作者,博士,教授。研究方向:SiC 功率器件封装。E-mail: zengerzheng@126.com。

3D Packaging for Low-inductance Bidirectional Switch of SiC Power Module
Siyuan WANG1 , Yuxi LIANG2 , Peng SUN2 , Mingrui ZOU2 , Jiakun GONG2 , Zheng ZENG2
Affiliations
  • 1 CQU-UC Joint Co-Op Institute, Chongqing University Chongqing 400044 China
  • 2 School of Electrical Engineering Chongqing University Chongqing 400044 China
出版时间: 2024-05-30 doi: 10.13234/j.issn.2095-2805.2024.3.87
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双向开关在固态断路器、光伏逆变器等领域具有不可替代的作用,而低损耗、高开关频率的双向开关SiC功率模块得到了越来越多的关注。然而,现有双向开关SiC功率模块仍然沿用传统Si功率模块的封装方法,难以适应SiC器件的高速开关优势。针对双向开关SiC功率模块的低感封装需求,提出一种芯片堆叠的3D封装集成方法。给出了3D封装的电路拓扑和几何结构,分析3D封装的换流回路和寄生电感规律,设计3D封装的技术工艺,并研制了双向开关SiC功率模块样机。采用双脉冲测试的实验结果验证了所提3D封装双向开关SiC功率模块的可行性和有效性。

双向开关  /  SiC 功率模块  /  低寄生电感  /  3D封装

The bidirectional switch is extensively applied in the fields such as state-solid breakers and photovoltaic inverters, and increasing attention is paid to the bidirectional switch of SiC power modules owing to its low power loss and high switching frequency. However, due to the traditional packaging methods for Si power modules, the bidirectional switch of the SiC power module is challenged by the issue of high switching speed. Aimed at the low-inductance packaging requirement, a chip-on-chip 3D packaging method is proposed for the bidirectional switch of the SiC power module. The circuit topology and geometric structure of the 3D packaging are given, and the communication loop and parasitic inductance of the 3D packaging are analyzed. In addition, the process was designed for the 3D packaging, and a prototype of the bidirectional switch of the SiC power module was fabricated. Experimental results of a double-pulse test verified the feasibility and effectiveness of the proposed 3D packaging for the bidirectional switch of the SiC power module.

Bidirectional switch  /  SiC power module  /  low parasitic inductance  /  3D packaging
王思媛, 梁钰茜, 孙鹏, 邹铭锐, 龚佳坤, 曾正. 基于3D封装的低感双向开关 SiC 功率模块研究. 电源学报, 2024 , 22 (3) : 87 -92 . DOI: 10.13234/j.issn.2095-2805.2024.3.87
Siyuan WANG, Yuxi LIANG, Peng SUN, Mingrui ZOU, Jiakun GONG, Zheng ZENG. 3D Packaging for Low-inductance Bidirectional Switch of SiC Power Module[J]. Journal of Power Supply, 2024 , 22 (3) : 87 -92 . DOI: 10.13234/j.issn.2095-2805.2024.3.87
随着电动汽车、新能源发电和储能等领域的持续快速发展,为了保障安全、可靠和高效的双向电能流动,双向开关具有重要的应用价值[1]。相对于传统的$\mathrm{{Si}}$ 功率模块,得益于更高的工作结温、击穿电压、开关频率和能量转换效率等优势[2],双向开关 SiC 功率模块具有更高的技术经济效益, 在电源管理、电池保护、电机控制和光伏发电等领域得到了广泛的关注[3]。目前,双向开关主要通过 1 颗双向导通的芯片或 2 颗传统芯片封装集成来实现。双向导通的$\mathrm{{SiC}}$ 芯片需要复杂的背面工艺,工艺难度大, 芯片成本高[4]。因此,通常采用 SiC MOSFET 芯片反并联集成封装到 1 个模块内,得到双向开关$\mathrm{{SiC}}$ 功率模块。
针对双向开关$\mathrm{{SiC}}$ 功率模块已有部分研究,主要集中在封装工艺和封装结构等方面。在封装工艺方面, 双向开关功率模块主要用作断路器, 通流能力强, 功率损耗大, 开关速度快, 对封装的电流密度、结-壳热阻和寄生电感要求比较高。现有封装的双向开关$\mathrm{{SiC}}$ 功率模块主要以电热性能、机械性能和可靠性为主要优化目标[5],但是大多仍然沿用传统$\mathrm{{Si}}$ 功率模块的封装结构[6]。现有双向开关功率模块多为平面型传统封装, 内部采用引线键合结构, 且受限于二维换流回路结构, 存在寄生电感大、封装体积大、功率密度低、制造成本高和工艺难度大等问题[7],难以适应具有高速开关特性的$\mathrm{{SiC}}$ 功率器件,限制了双向开关$\mathrm{{SiC}}$ 功率模块的应用优势, 无法满足双向开关$\mathrm{{SiC}}$ 功率器件朝轻量化、高功率密度化的后期发展[6]。为了降低$\mathrm{{SiC}}$ 功率模块的封装寄生电感,可以利用层叠柔性母排,基于磁路相消的原理,降低封装的互联寄生电感[8]。此外,也可以采用印刷电路板 PCB(printed circuit board) 和陶瓷直接覆铜板 DBC(direct bonded copper)的混合封装技术,使用 PCB 板灵活走线,降低回路厂区,减小寄生电感[9-10]。为了进一步缩短封装寄生回路,可以采用功率芯片堆叠结构 PCOC(power chip-on-chip) 的概念[11],将 2 颗功率芯片垂直布局,以减小功率回路长度,从而降低寄生电感。
针对双向开关$\mathrm{{SiC}}$ 功率模块的低感封装需求, 本文提出了一种基于芯片堆叠的双向开关$\mathrm{{SiC}}$ 功率模块 3D 封装方法, 以实现在寄生电感、功率密度、实现难度和经济成本上较好的平衡。首先,给出了双向开关$\mathrm{{SiC}}$ 功率模块的封装结构,对比分析了传统平面型封装和所提 3D 封装的换流回路;然后, 基于 ANSYS Q3D 分析工具, 分析了 3D 封装的寄生电感分布特性;最后,研制了 3D 封装双向开关$\mathrm{{SiC}}$ 功率模块样机,基于双脉冲测试实验结果, 验证了所提 3D 封装的可行性和有效性, 为双向开关$\mathrm{{SiC}}$ 功率模块的低感封装设计提供了新的思路。
商业化双向开关功率模块的现状如图1 所示。 额定电压在${600}\mathrm{\;V}$ 以下双向开关功率模块的典型封装主要有 QFN、T3A 和 SOT 等,额定电压在 700~${1200}\mathrm{\;V}$ 的双向开关功率模块的典型封装主要为 T-Type、EasyPack 和 SP3F 等。可见, 现有双向开关功率模块采用传统封装技术时的寄生电感大,难以适应第三代半导体功率器件应用。
双向开关$\mathrm{{SiC}}$ 功率模块的电路原理和封装结构如图2 所示。针对如图2(a) 所示的双向开关电路,本文提出了一种基于$3\mathrm{D}$ 堆叠封装的$\mathrm{{SiC}}$ 功率模块, 如图2(b)所示。该 SiC 功率模块采用上、下层 2 颗 SiC 芯片组成共源极双向开关结构, 具有双面散热、无键合线的紧凑结构, 模块的尺寸为 29$\mathrm{{mm}}\times {15.88}\mathrm{\;{mm}}\times {3.12}\mathrm{\;{mm}}$,远小于传统单面散热功率模块或分立器件。该双向开关为 3 层结构,其中转接层与芯片的开尔文源极和栅极连接, 上、下层 DBC 与芯片的漏极连接。转接板设置了 246 个直径为${15.7}\mathrm{{mil}}$ 的通孔,以保证上、下层芯片的功率源极连接。DBC 为铜-陶瓷-铜结构,用于绝缘和导热,双层 DBC 结构可形成双面散热,从而降低功率模块的结-壳热阻[12]。芯片在转接板的上、下层对称分布, 采用垂直互连的结构以减小功率回路长度, 降低功率模块的寄生电感[13]。功率端子对称分布于转接板,通过焊料层与上、下层 DBC 连接。模块内部共有 2 条电流路径, 当上层芯片开通时电流流经路径 1, 当下层芯片开通时电流流经路径 2, 具体的电流路径如图2(b) 所示[5]
采用传统平面键合线封装互连技术,双向开关 SiC 功率模块的封装寄生电感较大[14],甚至会超过${12}{\mathrm{{nH}}}^{\left\lbrack {15}\right\rbrack }$,其寄生参数的分布如图3 所示。此外,直流母线电容的等效串联电感 ESL(equivalent series inductance) 和直流母排的寄生电感也会进一步导致 SiC 器件开关过程中的电压过冲, 增加器件损耗, 引起电磁干扰, 降低器件安全工作区, 进而影响功率模块的可靠性和稳定性[16]。功率模块的电压过冲$\Delta {v}_{\mathrm{{ds}}}$ 可表示为
$\Delta {v}_{\mathrm{{ds}}}= \left({{L}_{\mathrm{{ESL}}}+ {L}_{\mathrm{{bus}}}+ {L}_{\mathrm{{dl}}}+ {L}_{\mathrm{{sl}}}+ {L}_{\mathrm{d}2}+ {L}_{\mathrm{s}2}+ {L}_{\mathrm{d}3}+ {L}_{\mathrm{s}3}+ {L}_{\mathrm{d}4}+ }\right.\\\left.{{L}_{\mathrm{s}4}+ {L}_{\mathrm{{com}}}}\right)\mathrm{d}{i}_{\mathrm{d}}/\mathrm{d}t $
式中:${L}_{\mathrm{{ESL}}}$${L}_{\text{bus }}$ 分别为母线电容和母线的寄生电感;${L}_{\mathrm{d}i}$${L}_{\mathrm{s}i}$ 分别为芯片漏极和源极的寄生电感,$i =$ $1,2,3,4;{L}_{\mathrm{{com}}}$ 为转接板及其通孔的寄生电感。
基于图2 所提出的双向开关$\mathrm{{SiC}}$ 功率模块$3\mathrm{D}$ 封装,可以基本消除传统封装的寄生电感,具体换流回路如图3 所示。所提 3D 封装功率模块的寄生电感主要由${L}_{\text{com }}$ 决定,并受转接板通孔的数量和大小影响[17]
基于图2 所提的$3\mathrm{D}$ 封装结构,使用 ANSYS Q3D 软件提取双向开关$\mathrm{{SiC}}$ 功率模块的寄生电感。 根据图3(a) 所示的等效换流电路可以看出, 功率模块的寄生电感主要包括 3 个部分:第 1 部分是从功率端子 1 到上层芯片的漏极;第 2 部分是从上层芯片的漏极到下层芯片的漏极;第 3 部分是从下层芯片的漏极到功率端子 2。因此, 功率模块的寄生电感网络$\mathbf{L}$ 可表示为
$\mathbf{L}= \left\lbrack \begin{array}{lll}{L}_{11}& {M}_{12}& {M}_{13}\\{M}_{21}& {L}_{22}& {M}_{23}\\{M}_{31}& {M}_{32}& {L}_{33}\end{array}\right\rbrack $
式中,${L}_{ij}$${M}_{ij}$ 分别为模块每一部分寄生电感的自感和互感,$i\text{、}j = 1,2,3$。因此,模块的回路寄生电感${L}_{\sigma }$ 可以表示为
${L}_{\sigma }= {L}_{11}+ {L}_{22}+ {L}_{33}+ 2\left({{M}_{12}+ {M}_{13}+ {M}_{32}}\right)$
基于 ANSYS Q3D 的仿真结果, 可以得到功率模块的磁场强度分布, 如图4 所示。可见, 功率模块的磁场主要分布在芯片附近,也即芯片之间的互联转接板是寄生电感的主要来源。
计算${10}\mathrm{{MHz}}$ 交流激励下功率模块的寄生电感[18],结果如表1 所示。根据式 (3) 和表1, 可以计算得到功率模块的寄生电感为${3.9}\mathrm{{nH}}$。可见,芯片的堆叠封装结构显著缩短了垂直换流路径的长度, 此外, 折叠和重叠的换流回路能实现较好地磁场相消,共同保证较低的封装寄生电感,以适应$\mathrm{{SiC}}$ 功率器件的高$\mathrm{d}i/\mathrm{d}t$ 应用。
为了验证所提 3D 封装双向开关$\mathrm{{SiC}}$ 功率模块的有效性和可行性, 本文研制了功率模块样机, 并开展了双脉冲测试实验研究。
采用${17}\mathrm{\;m}\Omega$ 的 SiC MOSFET 芯片作为双向开关功率模块的主功率芯片, 3D 封装的制备过程如图5 所示。
首先通过夹具对下层$\mathrm{{DBC}}$ 、下层芯片和转接板进行定位, 然后使用夹具对上层 DBC 和上层芯片进行定位, 再使用真空回流工艺对功率模块进行整体焊接。功率模块整体使用同一熔点的焊料, 以保证功率模块结构的稳定性以及焊接的质量。最后,将功率模块的各端子与测试母版连接,进行双脉冲测试。
为了表征所研制$3\mathrm{D}$ 封装双向开关的开关特性, 基于图3(b) 所示的双脉冲测试原理, 搭建如图6 所示的测试平台,关键参数如表2 所示。
双脉冲实验平台包括驱动电源、直流电压源、2 个待测功率模块、负荷电感、罗氏线圈、电压探头、 示波器和信号发生器, 2 个待测功率模块串联构成半桥结构,以下桥臂功率模块为测量对象。其中,上桥臂功率模块上层芯片的开尔文源极和栅极短接, 下层芯片的开尔文源极和栅极接入${20}\mathrm{\;V}$ 电压信号,下桥臂功率模块上层芯片的开尔文源极和栅极接入双脉冲控制信号,下桥臂功率模块下层芯片的开尔文源极和栅极接入${20}\mathrm{\;V}$ 电压信号,负荷电感为${200\mu }{\mathrm{H}}_{\circ }$ 本实验采用信号发生器产生双脉冲控制信号, 使用高带宽的差分探头测量交流端子和直流负极之间的电压,使用罗氏线圈捕获下桥臂电流。
在直流母线电压${300}\sim {600}\mathrm{\;V}$ 、负载电流${20}\mathrm{\;A}$ 条件下开展实验研究, 实验波形如图7 所示。在测试过程中,驱动双脉冲的时间分别为${5\mu }\mathrm{s}$${2\mu }\mathrm{s}$。 在${600}\mathrm{\;V}/{20}\mathrm{\;A}$ 的测试条件下,测得双向开关功率模块的开通及关断波形, 在关断时刻, 漏源级电压上升至${600}\mathrm{\;V}$,并伴有${85}\mathrm{\;V}$ 电压的超调,其振荡频率为${32.26}\mathrm{{MHz}}$。为了评估器件的开关损耗,计算器件开关过程的能量为
$ E ={\int }_{{t}_{1}}^{{t}_{2}}{v}_{\mathrm{{ds}}}{i}_{\mathrm{d}}\mathrm{d}t $
式中:对于开通过程,${t}_{1}$ 为漏极电流${i}_{\mathrm{d}}$ 上升到${10}\%$ 负载电流的时刻,${t}_{2}$ 为漏-源极电压${v}_{\mathrm{{ds}}}$ 下降到${10}\%$ 直流侧电压时刻;对于关断过程,${t}_{1}$ 为漏极电压${v}_{\mathrm{{ds}}}$ 上升到${10}\%$ 直流侧电压时刻,${t}_{2}$ 为漏极电流${i}_{\mathrm{d}}$ 下降到${10}\%$ 负载电流的时刻。由式 (4) 可计算得到功率模块的开通损耗为${310.32\mu }\mathrm{J}$,关断损耗为${1105.7\mu }\mathrm{J}$
可以发现, 模块在不同直流母线电压条件下的开关特性基本一致, 由于模块的寄生电感小, 测试结果没有出现明显的电压、电流过冲,从而确保了模块的可行性。
针对双向开关$\mathrm{{SiC}}$ 功率模块的低寄生电感技术需求,本文提出了一种芯片堆叠的 3D 封装集成方法。相对于传统平面布局封装,所提 3D 封装功率回路具有折叠相消的优势, 同时采用无键合线封装工艺显著降低封装寄生电感,实现了具有较高可靠性的高功率密度模块。本文建立了$3\mathrm{D}$ 封装寄生电感的数学模型, 并分析了寄生电感的主要分布, 基于 ANSYS Q3D 提取 3D 封装功率模块的寄生电感约为${3.9}\mathrm{{nH}}$。基于$3\mathrm{D}$ 封装功率模块的制造工艺研制了双向开关功率模块样机,并采用双脉冲测试方法, 验证了所提 3D 封装双向开关 SiC 功率模块的可行性和有效性。
  • 国家自然科学基金资助项目(52177169)
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2024年第22卷第3期
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doi: 10.13234/j.issn.2095-2805.2024.3.87
  • 接收时间:2024-02-03
  • 首发时间:2025-07-21
  • 出版时间:2024-05-30
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  • 收稿日期:2024-02-03
  • 修回日期:2024-02-14
  • 录用日期:2024-02-23
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National Natural Science Foundation of China(52177169)
国家自然科学基金资助项目(52177169)
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    1 重庆大学辛辛那提大学联合学院 重庆 400044
    2 重庆大学 电气工程学院 重庆 400044
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