Shape Optimization of High-Stress-Buffering Bridge-Typed Spacers for Double-Sided Power Modules

Owing to their superior characteristics of high thermal dissipation and low parasitic inductance, double-side-cooled (DSC) power modules have garnered extensive research attention. Optimizing the spacer structures has emerged as a focus to mitigate the stresses induced by thermal expansion mismatches and prolong the modules’ life cycles. In this paper, a topology optimization (TO) design for the shapes of bridge-typed spacers (BTSs) in a DSC module is proposed, considering simultaneously thermal and stress impacts. The thermo-mechanical stress distributions in the module are investigated to decide the co-related and decoupled thermal and stress efforts of the BTSs. A topology optimization (TO) approach is then developed for the BTSs’ shapes from both thermal and mechanical perspectives, including the TO design considerations and settings decided based on the analyses. The TO designs are conducted to identify the optimal spacer shapes, with the proper objective determined.