Miniaturization, Packaging, and Thermal Analysis of Power Electronics Modules by Alexander B ...

138 Pages·1999·2.8 MB·English

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Alexander B. Lostetter
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Acknowledgments
Trust your wings to lift you, and though at first you may feel as if you’re falling,
in the end it is towards the heavens that you will fly. To do this though, you must make
that initial step of faith into the unknown.
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TABLE OF CONTENTS
CHAPTER 1. INTRODUCTION 1
CHAPTER 2. THE BASIC THEORY OF POWER
TRANSISTOR DEVICES 4
CHAPTER 3. POWER ELECTRONICS CIRCUIT DESIGN
THEORY 11
3.1 Introduction to Power Circuit Design 11
3.2 Pulsewidth Modulated Switching Basics 12
3.3 Circuit Fundamentals and Topology 12
3.3.1 Buck Topology 12
3.3.2 Boost Topology 13
3.3.3 Buck/Boost Topology 13
3.3.4 Flyback Topology 13
3.3.5 Half-Bridge Topology 14
3.3.6 Push-Pull Topology 14
3.3.7 Full-Bridge Topology 14
3.4 Transformer and Magnetics Design 15
3.5 Output Filter Design 15
3.6 Power Switch and Driver Design 16
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3.7 Controller and Driver Design 16
3.8 Feedback Design 17
3.9 Circuit Start-up Design 18
3.10 Protection Design 18
CHAPTER 4. HALF BRIDGE POWER CONVERTER, CONTROL,
DRIVER, AND LOAD CIRCUITRY DESIGN 28
4.1 Half-Bridge Power Converter Design 28
4.2 Control and Driver Circuitry Design 30
4.2.1 Programmable Oscillator Frequency 31
4.2.2 Dropping Resistor 31
4.2.3 Clamping Capacitors 32
4.2.4 Blocking Diode 33
4.3 Load Circuitry Design 33
4.4 Electrical Testbed for Power Electronics Module 36
4.5 Testing of the Electrical Testbed 36
CHAPTER 5. DESIGN AND FABRICATION OF POWER
ELECTRONICS MODULE 48
5.1 Single Metallization Layer Wirebond Module 48
5.2 Single Layer Wirebond Module Fabrication 49
5.3 Multi Metallization Layer Power Module Design 50
5.4 Multi Metallization Layer Power Module Fabrication 52
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5.5 Module Testing 53
CHAPTER 6. POWER MODULE THERMAL ANALYSIS 64
6.1 Thermal Issues with Power Electronics Modules 64
6.2 Three Dimensional Thermal Computer Simulations 67
6.3 Experimental Thermal Testing 76
CHAPTER 7. CONCLUSIONS 94
APPENDIX A 96
BIBLIOGRAPHY 119
VITA 126
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LIST OF FIGURES
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