#Japan #Tokyo #Thermal Insulation #Sumitomo Bakelite #Power Modules

Introduction

Sumitomo Bakelite Co., Ltd., headquartered in Shinagawa, Tokyo, has recently introduced advanced thermal insulation sheets that exemplify industry-leading thermal conductivity and insulation properties. These innovative products have been adopted as insulation layers for resin-insulated substrates made by Nihon Hassho Co., Ltd. in power modules used in Denso’s automotive inverters. This represents a significant shift from traditional ceramic substrates, paving the way for enhanced efficiency and performance in various applications.

Background

Power modules are essential devices at the core of power conversion and control systems, widely utilized across various sectors, including industrial equipment, automotive, renewable energy, and consumer electronics. The adoption of silicon carbide (SiC) power semiconductors has pushed for even higher performance levels recently, particularly in the automotive industry, where power modules are integral to electric vehicles (EVs) and plug-in hybrid vehicles (PHEVs). These components contribute significantly to extending vehicle range, improving energy efficiency, and reducing CO2 emissions.

As electric vehicles evolve, power modules must accommodate increasing current and voltage demands. Managing the heat generated during operation has become imperative. Sumitomo Bakelite has been diligently developing thermal insulation sheets that meet the high thermal conductivity and insulation requirements of power module components since 2018, progressing towards mass production.


Image is for illustrative purposes only and may differ from actual products.

Introducing BLA-6051 Thermal Insulation Sheet

The BLA-6051 thermal insulation sheet is a thermosetting resin adhesive sheet characterized by its excellent thermal conductivity and electrical insulation properties. By utilizing this innovative material as the insulation layer of resin-insulated substrates, it effectively replaces traditional ceramic substrates. Sumitomo Bakelite has created a proprietary resin with high thermal conductivity that, when blended into these insulation sheets, results in the following five key features:

1. Industry-Leading Thermal Conductivity

By employing a high heat-resistant resin combined with boron nitride (BN) filler orientation control technology, the BLA-6051 achieves low thermal resistance comparable to that of silicon nitride (AMB substrates). This enhanced thermal management significantly improves the heat dissipation performance of electronic and industrial devices, thus enhancing overall product reliability by mitigating temperature rises.

2. Excellent High-Voltage Performance

Crafted with essential insulation properties, this sheet ensures safety and reliable performance, making it suitable for high-voltage environments without compromise.

3. Achieving Thin Film Properties

The unique characteristics of the resin enable thin film applications, which contribute to lightweight designs and enhance the versatility for next-generation product development.

4. Dimensional Stability with Minimal Warping

The thermal insulation sheet boasts heat-resistive properties continuous at temperatures surpassing 150°C. This stability ensures superior performance in the processes of semiconductor chip implementation and power module assembly, leading to streamlined processing steps and improved yield rates.

5. Replacement for Ceramic Substrates

By substituting ceramic substrates with resin-insulated types, manufacturers can expect cost reductions while maintaining high performance characteristics, ultimately overcoming the limitations associated with ceramic materials.

Future Plans

Currently, Sumitomo Bakelite targets the automotive sector for increasing sales while expanding applications into industrial inverters, renewable energy, and factory automation. The company aims to achieve a sales scale of 10 billion yen by 2035, highlighting its strong growth trajectory.

For more information and inquiries, please contact:
Sumitomo Bakelite Co., Ltd.
Heat Dissipation Materials Development Department
TEL: 03-5462-4262
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