Direct Liquid-Cooled Power Modules for Commercial EV Drivetrains

By eliminating multiple thermal-interface layers, the approach significantly reduces thermal resistance and lowers junction temperatures, improving device utilization and efficiency. Prototype modules using 1200 V IGBTs and freewheeling diodes with tab-and-clip interconnection technology were evaluated through thermal measurements, double-pulse testing, and mission-profile simulations.

Results demonstrate reduced chip temperatures, lower losses, and increased thermal margin compared with conventional module-on-cold-plate designs. Additionally, reduced temperature swing contributes to improved lifetime and reliability, while the simplified assembly reduces complexity and material usage. This concept supports the development of high-power-density traction inverter systems for commercial vehicle drivetrains and other electrified applications.

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