Overcoming Challenges in High-Power Electronics Manufacturing
Power electronics is a rapidly evolving field, driven by advancements in technology, increasing demand for energy efficiency, and the shift towards renewable energy sources.
Ensuring Reliability and Longevity with Advanced Surface Treatment
In the realm of high-power electronics, the drive towards miniaturization and higher performance has brought forth a set of intricate challenges. Ensuring the seamless integration of diverse materials is crucial for the reliability and longevity of power electronics that manage currents exceeding 1000 A. Imperfections like voids and oxidation on metal surfaces can severely compromise the performance and safety of these components.
Plasmatreat's Openair-Plasma® cleaning and activation, along with the innovative REDOX-Tool, provide advanced solutions to address these critical challenges effectively. By ensuring pristine, oxide-free surfaces, these innovations enhance adhesion, electrical performance, and overall reliability, paving the way for the next generation of high-performance electronics.
Challenges in Semiconductor and Power Module Production
Tough Demands on Materials and Interconnections
High-performance power modules must operate reliably for years under extreme conditions. Whether in electric vehicles, wind turbines, or industrial drives, these components are exposed to high temperatures, high voltages, and intense mechanical stress – all within increasingly compact designs.
A particular challenge lies at so-called “triple points,” where different materials such as copper, ceramics, and potting compounds meet. These zones are prone to stress, trapped air, or adhesion failure – all of which can shorten the module’s lifespan. One of the root causes: oxidized metal surfaces that compromise solderability and increase contact resistance. Epoxy delamination during overmolding is another common risk. To address these issues, reliable interconnect technology and targeted surface treatment are essential.
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Use Cases – Where Plasma Makes the Difference
Application Areas Across High-Demand Industries
Our plasma systems are used wherever power modules are exposed to extreme conditions and need to perform reliably. Different industries face different challenges – but the solution remains the same: advanced surface treatment with Openair-Plasma® and PlasmaPlus®.
E-Mobility
In inverters, battery management systems, and charging units, plasma ensures stable electrical contacts and prevents delamination in highly dynamic environments with intense heat and current loads.
Renewable Energy
Photovoltaic and wind energy systems require long-term durability despite exposure to UV radiation, moisture, and temperature swings. Plasma coatings help protect critical contact areas and improve reliability.
Industrial Automation
Power modules in industrial and robotic systems must withstand vibration, dust, and harsh media. Plasma treatment improves adhesion of potting compounds and ensures long-lasting, high-integrity connections.
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Key challenges include:
Voids in Solder Joints
- Thermal and Electrical Impedance: Voids can reduce the thermal and electrical conductivity of solder joints. This can lead to hotspots, increased resistance, and potential failures due to overheating.
- Mechanical Weakness: Voids compromise the mechanical integrity of solder joints, making them more susceptible to cracking and failure under thermal and mechanical stress.
Oxidation of Metal Surfaces
- Poor Adhesion: Oxidized surfaces hinder proper bonding between materials, which can result in delamination or poor mechanical strength of the assembled components.
- Inconsistent Soldering: Oxides create barriers that prevent solder from wetting and spreading uniformly, leading to weak and unreliable solder joints.
Material Compatibility
- Thermal Expansion Mismatch: Different materials have different coefficients of thermal expansion. Without proper surface treatment and bonding techniques, thermal cycling can cause stresses that lead to delamination or cracking.
- Chemical Incompatibility: Materials must be carefully selected and treated to prevent chemical reactions that can degrade performance or cause failures.
Flux Residue
- Contamination: Flux residues can contaminate the assembly, leading to electrical shorts, corrosion, and reliability issues.
- Cleaning Challenges: As components become smaller and more densely packed, removing flux residues without damaging the components becomes increasingly difficult.
Miniaturization
- Precision Requirements: Smaller components and finer pitches require extremely precise manufacturing processes. Even minor imperfections can lead to significant performance issues or failures.
- Heat Dissipation: Efficient heat dissipation becomes more challenging as the size of components decreases, necessitating high-quality solder joints and materials to manage heat effectively
Long-Term Reliability
- Environmental Exposure: Power electronics are often exposed to harsh environments, including high temperatures, humidity, and vibration. Ensuring that all materials and joints are free from voids and defects is critical for maintaining long-term reliability.
- Aging and Degradation: Over time, materials can degrade, and joints can weaken. Voids and imperfections accelerate this process, leading to early failures.
Addressing these challenges
Techniques such as the Openair-Plasma® technology and the REDOX-Tool's inline oxide reduction can effectively clean and prepare surfaces, ensuring that all materials bond properly and function reliably even under the high demands of power electronics.
This results in improved electrical performance, higher yield rates, and enhanced overall reliability and longevity of the components.
How Plasmatreat Can Help with Openair-Plasma®
Improved Adhesion and Bonding
When using sintering processes, the parts will see higher temperatures, which can result in delamination issues. Plasmatreat has come up with a combined solution that first eliminates the oxide layer by the REDOX tool and secondly applies a nano layer to ensure a good bond with the mold material.
Oxide Reduction with the REDOX®-Tool
The REDOX-Tool utilizes a combination of nitrogen and hydrogen in a tunnel concept. This process provides a pristine surface for subsequent processes. By eliminating oxide layers, the REDOX-Tool enhances electrical conductivity and reliability, which is crucial for high-performance electronic components like power modules and IGBTs.
Continuous and Efficient Processing
The REDOX®-Tool supports continuous inline processing, allowing for the treatment of materials as they move through the production line. This reduces downtime and increases overall manufacturing throughput. Moreover, it ensures continuous process control for every part, leading to consistent quality and performance.
Reduction of Defects and Improved Yield Rates
The thorough cleaning and oxide reduction processes minimize the risk of voids and other defects, which are critical for the long-term reliability and performance of high-power electronics. Cleaner surfaces and improved bonding result in fewer defects and rework, leading to higher yield rates and reduced waste in production.
Environmental and Cost Benefits
By minimizing the reliance on chemical fluxes and cleaning agents, Plasmatreat's solutions reduce the environmental impact of the manufacturing process. Improved process efficiency, higher yields, and reduced consumable usage contribute to significant cost savings over time.
