Thermal Analyses of Power Electronics Integrated with Vapour Chamber Cooling
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Thermal Analyses of Power Electronics Integrated with Vapour Chamber Cooling Yiyi Chen1,2 · Yuying Yan1,3 · Bo Li1 Received: 28 March 2020 / Accepted: 3 October 2020 © The Author(s) 2020
Abstract Insulated gate bipolar transistor (IGBT) power module is used for power switching transistor devices in the power supply and motor control circuits in both hybrid electric vehicles and electric vehicles. The target of heat flux of IGBT is continuously increasing due to the demand for power rating improvements and miniaturisation. Without suitable efficient cooling technologies, excessively high temperature and uneven temperature distribution can cause high thermal stress, eventually leading to severe module failures. Therefore, highly efficient cooling solutions are highly required. Vapour chamber with phase change can provide quick heat transfer and low temperature gradient. This study proposes a new IGBT structure integrated with vapour chamber. The tests and simulation results indicate that the thermal and thermo-mechanical performances of IGBT integrated with vapour chamber are better than those of the IGBT with copper baseplate module. The thermal resistance between the junction and heat sink is reduced from 0.25 to 0.14 °C/W, and the temperature uniformity is greatly improved due to the phase change in the vapour chamber. The simulation also investigates the thermal stress distribution, deformation and thermal fatigue lifespan of IGBT power electronics module. A reduction of 21.8% in thermal stress and an increase of 9% in lifespan of Sn–3.5Ag solder are achieved. Keywords Power electronics · IGBT · Phase change cooling · Thermal performances · Thermal fatigue lifespan Abbreviations DBC Direct bonded copper EV Electric vehicle HEV Hybrid electric vehicle IGBT Insulated gate bipolar transistor
inverter is used to distribute and convert the direct current from battery to alternating current [1]. It also switches with high speed for satisfying the current frequency requirement. Therefore, the IGBT power electronics module is considered as the heart of the electric drivetrain.
1 Introduction
1.1 Thermal Challenges of IGBT Modules in EVs and HEVs
From the viewpoint of protecting the global environment, the reduction of carbon dioxide emissions has been required. Hybrid electric vehicles (HEVs) and electric vehicles (EVs) tend to have lower carbon dioxide emissions. The insulated gate bipolar transistor (IGBT) power electronics in the * Yuying Yan [email protected] 1
Faculty of Engineering, University of Nottingham, Nottingham NG7 2RD, UK
2
Dynex Semiconductor Limited, Doddington Road, Lincoln LN6 3LF, UK
3
Research Centre for Fluids and Thermal Engineering, University of Nottingham, Ningbo 315100, China
IGBT modules must operate stably during the whole vehicle’s lifespan to maintain a safe condition in EVs and HEVs. The loss from IGBT module is in the form of heat energy during normal switching operation, which has the possibility to cause power electronics faults. The heat flux of IGBT
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