USA flag logo/image

An Official Website of the United States Government

Structured Copper: A Potential Solution for Manufacturing High Power

Award Information

Department of Defense
Award ID:
Program Year/Program:
1997 / SBIR
Agency Tracking Number:
Solicitation Year:
Solicitation Topic Code:
Solicitation Number:
Small Business Information
Silicon Power Corporation
275 Great Valley Parkway Malvern, PA 19355-1308
View profile »
Woman-Owned: No
Minority-Owned: Yes
HUBZone-Owned: No
Phase 2
Fiscal Year: 1997
Title: Structured Copper: A Potential Solution for Manufacturing High Power
Agency / Branch: DOD / NAVY
Contract: N/A
Award Amount: $1,905,251.00


Reliable and efficient heat removal from silicon high power semiconductor devices is a major technical challenge. SPCO owns key technology which offers a highly reliable method of heat removal which causes virtually no material fatigue of the semiconductor or the bonding materials. This proposed bonding technique is based on longitudinally pliable direct-bonded structured copper. This technology allows encapsulation of multiple high power devices in a double side cooled module, very similar to medium power single side cooled IGBT module. The structured copper bonding technique offers at a temperature variation of 40C a life well above 15 million cycles while existing module bonding techniques under the same conditions barely reach 0.5 million cycles. Through the concept has been proven with diodes and SCRs, no work was performed on GTOs or MTOs. Additionally, a sizable work still needs to be done for process improvement before it becomes technically feasible for manufacturing. Phase I study is aimed at establishing eh optimum process and to investigate issues relating the use of structured copper with free-floating silicon devices and devices with large interdigitated structures. Applicability of this process to medium power IGBT or MCT modules will also be investigated.

Principal Investigator:

Dr. Rik De Doncker

Business Contact:

Small Business Information at Submission:

Silicon Power Corp.
175 Great Valley Pkwy Malvern, PA 19355

Number of Employees:
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No