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DOE OSTI · 3022361

Rapid Prototyping Techniques for Organic Direct-Bonded-Copper Power Modules

Zhao, Shuofeng [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000208021979)·Major, Joshua [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000194240643)·DeVoto, Douglas [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000348179647)·Khan, Faisal [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0009000000229954)·Narumanchi, Sreekant [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000153376069)
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Abstract

Organic Direct-Bonded-Copper (ODBC) is a novel packaging technology for power modules which allows higher flexibility in layout design. In this work, a set of rapid prototyping techniques are developed for ODBC modules based on a polyimide dielectric material. These techniques enable fast and low-cost fabrication of modules with 3-Dimensional (3D) layout features. An example half-bridge (HB) silicon carbide (SiC) metal oxide semiconductor field effect transistor (MOSFET) module is designed and prototyped using the proposed techniques aiming at ultra-low power loop inductance. Finite element analysis (FEA)-circuit co-simulations results and experimental results validate an approximately 0.71nH power loop inductance for the example module design.

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36 MATERIALS SCIENCEorganic direct-bonded copper (ODBC)parasitic inductancepower modulerapid prototyping

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Zhao, Shuofeng [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000208021979), Major, Joshua [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000194240643), DeVoto, Douglas [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000348179647), Khan, Faisal [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0009000000229954), Narumanchi, Sreekant [National Laboratory of the Rockies, Golden, CO (United States)] (ORCID:0000000153376069). 2025-09-29. Rapid Prototyping Techniques for Organic Direct-Bonded-Copper Power Modules. https://doi.org/10.1109/3d-peim64703.2025.11180279

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DOE OSTI2026

Cyclic moisture reactivation of calcium sorbents for long duration thermochemical energy storage

The transition to a flexible and reliable energy infrastructure, using electro-thermal energy generation technologies such as geothermal, concentrated solar power, and nuclear, usually demands simultaneous advancement of thermal energy storage (TES) to support on-demand electricity generation and industrial applications while mitigating the inherent intermittency of renewable energy sources and power outages from direct energy generation. Among TES technologies, thermochemical energy storage (TCES) based on calcium looping emerges as a compelling high-power energy storage candidate due to its high reaction enthalpy, compatibility with elevated operating temperatures, and abundance of low-cost materials. However, the long-term durability of calcium-based sorbents for TCES is hindered by surface sintering and particle aggregation, leading to performance degradation over repeated thermal cycles. This study explores a moisture hydration-based strategy to regenerate a degraded calcium sorbent and mitigate performance degradation for long duration TCES. The addition of moisture transforms calcium oxide into calcium hydroxide and produces intercalation water layers, associated with a regenerated surface area and reduced calcium oxide crystallite size. Both these effects are beneficial in restoring the sorbents' reactivity for carbonization. Additionally, an optimized hydration-assisted reactivation protocol balances the recovered energy storage capacity with heating penalty required for moisture removal from hydrated samples, resulting in an enhanced energy storage capacity up to 176% compared to benchmark sorbents that undergo cycling without reactivation after 60 cycles. In conclusion, these results highlight the potential of hydration-assisted reactivation to enhance the long-term performance of TCES, providing an effective pathway to advancing electro-thermal storage technologies.

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