Metal foil interconnection of electrical devices

Abstract

An electrical assembly () includes a power IC such as a MOSFET () attached to a substrate module (). The MOSFET includes a top surface comprising first and second conductive device surfaces (A, B), associated with first and second device ports, and a bottom surface comprising a third conductive device surface C associated with a third device port. A first foil element is bonded to the first conductive device surface(s) A and to each of the first conductive substrate surfaces (A, A) and provides a continuous conductive pathway from each conductive surface (A) to each other conductive surface (A) and to each conductive surface (A, A). A second foil element is bonded to the second conductive device surface(s) B and to the second conductive substrate surface Band provides a continuous conductive pathway from each device conductive surface (B) to the substrate conductive surface (B). A third foil element may be installed to electrically interconnect the discrete second device surfaces (B). The foil elements reduce interconnection parasitics and reduce charge and thermal energy density at device conductive surfaces as compared to wire bonded electrical interconnections. The foil elements may be comprised of formed metal elements that are flexible but sufficiently rigid to hold a formed shape or flexible foils supported on a flexible dielectric substrate.