US Patent 8120153 High-temperature, wirebondless, injection-molded, ultra-compact hybrid power module

A cost-effective, ultra-compact, hybrid power module packaging system and method for making allows device operation in conventional and high temperature ranges over 300° C. Double metal leadframes are directly bonded to the front- and backside of semiconductor chips, and injection-molded high temperature polymer materials encapsulate the module. The invention eliminates the use of unreliable metal wirebonds and solders joints, and expensive aluminum nitride ceramic substrates commonly used in conventional and high temperature hybrid power modules. Advantages of the new power modules include high current carrying capability, low package parasitic impedance, low thermo-mechanical stress under high temperature cycling, low package thermal resistance (double-side cooling), modularity for easy system-level integration, and low-cost manufacturing of devices compatible with current electronic packaging industry. A first embodiment uses molybdenum leadframes for operation in temperatures over 300° C.; a second embodiment of the invention, uses copper and copper alloy leadframes, provides benefits for conventional temperature electronics.