| SPS has been focusing on high power modules with thermal substrates for many years.
This is built on Courtney Furnivals last 20 years experience with Insulated Metal
and DBC substrates, and 30 years of experience with conventional thick-film hybrid
substrates. This experience includes his patents on high power modules for performance and
manufacturability. The patents reflect innovations with substrates, as well as associated
molded shells, leads, and coatings. These techniques have been applied to metal core
substrates, and to DBC substrates with both alumina and aluminum nitride ceramics. The thermal substrates have been used for surface mount and chip & wire modules. The modules have been used for 115, 230 and 460 VAC line products in the U.S. and Europe, and have addressed the corresponding regulatory agency evaluation and approval. SPS is currently under contract to Thermagon, Inc. to provide application support and new material evaluation for their premium thermal substrates and thermal multilayer boards. The Thermagon T-lam thermal substrates and boards are an insulated metal or metal core substrate. Courtney Furnival has written the design guidelines and application papers for the T-lam product. See the Thermagon "T-guide for Performance", "T-guide for Manufacturability" and "Thermal and High Current Multilayer PCB" on the Thermagon web site at www.Thermagon.com. The Thermagon T-lam products use a T-preg dielectric layer that is about 20 times more conductive than FR-4 materials. The T-lam can be thermally competitive with DBC, and much more economical. In addition to supporting T-lam applications, SPS works with board fabricators that have experience with T-lam materials, and with heavy copper foil boards and metal core substrates. These fabricators can implement the thermal dielectrics into higher power products that require superior thermal performance. These techniques are often used for planar magnetics PCBs. SPS has designed DBC/aluminum nitride power modules for automotive and stationary power generator application, and has built prototypes for these type products. The designs have included unique insert molded cases, heavy copper leads, metal matrix base plates, and low inductance laminated bus-bars. |
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