This thesis addresses the thermal management and reliability concerns of power semiconductor
devices from die to system level packaging design. Power electronics is a continuously
evolving and challenging field. Systems continue to evolve, demanding increasing
functionality within decreasing packaging volume, whilst maintaining stringent reliability
requirements. This typically means higher volumetric and gravimetric power densities, which
require effective thermal management solutions, to maintain junction temperatures of devices
below their maximum and to limit thermally induced stress for the packaging medium.
A comparison of thermal performance of Silicon and Silicon Carbide power semiconductor
devices mounted on Polycrystalline Diamond (PCD) and Aluminum Nitride (AlN) substrates
has been carried out. Detailed simulation and experimental analysis techniques show a 74%
reduction in junction to case thermal resistance (Rth (j-c)) can be achieved by replacing the AlN
insulating layer with PCD substrate. In order to improve the thermal performance and power
density of polycrystalline diamond substrates further at the system level, direct liquid cooling
technique of Direct Bonded Copper (DBC) substrates were performed.
An empirical model was used to analyse the geometric and thermo-hydraulic dependency upon
thermal performance of circular micro pins fins. Results show that micro pin fin direct cooling
of DBC can reduce the number of thermal layers in the system, and reduce the thermal
resistance by 59% when compared to conventional DBC cooling without a base plate.
Thermal management and packaging solutions for the wide band gap semiconductors, such as
GaN, is also described in detail. Comparisons of face up and flip chip thermal performance of
GaN on Sapphire, Silicon and 6H-SiC substrates in a T0-220 package system is presented.
Detailed thermal simulation results analysed using ANSYS® show that a flip chip mounted
GaN on sapphire substrate can reduce junction to case thermal resistance by 28% when
compared against the face up mounted technique
