This paper reports the performance
of an epoxy resin/silicon carbide
whisker (EP/SiCw) composite (1–5 wt %) as the field-dependent
conductivity (FDC) layer for electric field reduction in the high-voltage
power module. The experiments consist of a field emission scanning
electron microscope (FESEM), thermal conductivity, Fourier transform
infrared (FT-IR) spectroscopy, thermally stimulated discharge current
(TSDC), space charge, DC conductivity, and dielectric spectroscopy.
The DC conductivity and dielectric spectroscopy are used for DC and
AC stationary electric field simulations, respectively. The electric
field reduction of EP/SiCw composites in the power module is analyzed,
and the void defect in the FDC layer is also identified. The observed
percolation threshold of the EP/SiCw composites is 3 wt %, and the
DC electric field near the triple point decreases significantly by
74.8% under 10 kV when a 5 wt % EP/SiCw composite is applied for the
FDC layer. It was found that the efficient threshold operating frequency
of the FDC layer is around 10 kHz. The FDC layer can significantly
reduce the electric field under AC voltage below 10 kHz. Although
the power loss with the FDC layer increases obviously without the
FDC layer, it is still lower than 1 W at 1 MHz, which is negligible
for industrial applications. Notably, the void in the FDC layer is
identified by the slowly increased dielectric loss with the increase
of frequency through dielectric spectroscopy simulation.