IC Package Alumina Ceramic Washer for Heatsink Isolation and Heat Transfer

IC Package Al2O3 Ceramic Washer Applications

An alumina ceramic washer for an IC package is used in power electronics where a power device must be electrically isolated from the heatsink while maintaining a stable thermal path. The following three industries represent the highest usage volume and the strongest performance-driven requirements.

• Industrial Drives & Inverters – High-Load Thermal Interface Control

  ✅Key Advantages

  1. Lower device case temperature under continuous load
  Alumina’s thermal conductivity (approx. 24–29 W/m·K) reduces case temperature by 8–15 °C compared with insulating sheets rated only a few W/m·K, especially in compact inverter stages.

  2. Maintains thermal performance at elevated case temperatures
  Alumina maintains structure and conductivity at high temperatures up to 1500–1600 °C, preventing thermal softening or performance drift seen in polymer-based insulating pads.

  3. Supports uniform mounting pressure in high-torque assemblies
  The rigid washer surface distributes screw torque evenly across the TO-220 / TO-247 baseplate, reducing hotspots that typically occur under deformable thermal pads.

  ✅ Problem Solved

  A European inverter manufacturer found that during overload tests, several TO-247 IGBT stages exceeded the target case temperature by 10 °C, causing derating events. After replacing polymer pads with alumina ceramic washer for IC package, average case temperature decreased by 11–13 °C, and thermal cycling tests over 500 cycles showed no degradation in insulation or flatness. This reduced field overheating failures during the next deployment cycle.

• Welding Machines & High-Power Supplies – High-Voltage Isolation Stability

  ✅Key Advantages

  1. Higher dielectric withstand for high-voltage circuits
  With dielectric strength typically 12–22 kV/mm, alumina washers significantly increase insulation spacing between the live device tab and grounded heatsink in welding equipment.

  2. Prevents insulation drift during surge / transient events
  Unlike organic sheets that may carbonize or degrade under repetitive surge spikes, alumina’s inorganic structure remains stable, maintaining insulation even at high dv/dt stress levels.

  3. Provides rigid support for vibrating or shock-loaded assemblies
  In welding machines with high vibration, the ceramic’s stiffness prevents deformation around screw mounts, reducing insulation failures caused by frictional wear.

  ✅ Problem Solved

  A welding machine OEM reported intermittent breakdown during 3 kV insulation tests after 4–6 months of field use. Post-analysis showed degradation of polymer pads near the screw area. After switching to alumina ceramic washer for IC package, insulation tests passed consistently at 5 kV, and no breakdown events were recorded across 18 months of field monitoring.

• Automation & Control Cabinets – Long-Cycle Reliability in Continuous-Run Systems

  ✅Key Advantages

  1. Stable insulation performance under long-term thermal cycling
  Alumina maintains dielectric performance across hundreds of thermal cycles, preventing insulation reduction commonly seen in filled polymer pads.

  2. Minimal thermal ageing in continuous operation
  In cabinets with ambient temperatures of 50–70 °C, an alumina ceramic washer for an IC package maintains its thermal resistance curve with negligible drift over time, protecting component lifetime.

  3. Support for tight-spacing layouts in compact control cabinets
  High dielectric strength and controlled thickness (0.3–1.0 mm) allow design engineers to reduce creepage margins without compromising safety.

  ✅ Problem Solved

  An automation cabinet builder noticed rising IGBT case temperatures over a 12-month duty cycle, increasing from 72 °C to 83 °C, eventually causing premature module throttling. After implementing an alumina ceramic washer for the IC package with controlled thickness and improved flatness, the case temperature stabilized at 71–74 °C across extended 24/7 operation. No thermal derating events were observed during the following service cycle.

Al2O3 Ceramic Washer for IC Package Usage Instructions

• Installation

  1. Inspect alumina ceramic washer surfaces and edges before use; discard parts with visible cracks, chips or contamination.
  2. Apply a thin, uniform layer of thermal grease on the heatsink side or device side if your design requires thermal compound; avoid excessive thickness.
  3. Position the alumina ceramic washer for IC package so that the mounting and lead holes are aligned with the device and heatsink pattern.
  4. Insert the mounting screw through the device and washer into the heatsink and tighten gradually, using the torque recommended by the device manufacturer to avoid overstressing the package.

• Operation

  1. Ensure that heatsink surfaces are flat and clean to keep contact pressure uniform across the washer.
  2. Monitor device case temperature during initial validation; if abnormal hot spots appear, check washer seating and torque.
  3. Avoid mechanical shock or vibration that may introduce bending across the ceramic interface beyond the design limit.

• Storage

  1. Store alumina ceramic washer for IC package in the original inner packing to protect against dust and accidental impact.
  2. Keep cartons in a dry, clean area, away from corrosive chemicals or heavy loads that could cause mechanical damage.
  3. Avoid stacking heavy boxes directly on top of each other without suitable support.

• Cleaning and Handling

  1. Handle washers with gloves or finger cots to prevent oil contamination on the mating surfaces.
  2. If cleaning is necessary, use suitable solvent or deionized water and dry completely before installation; do not use coarse cloths that may scratch the surface.
  3. Do not drop washers onto hard surfaces; even small micro-cracks can propagate during thermal cycling.

• Common User Issues and Solutions

  1. Issue: Device case temperature remains high after installation.
  Possible causes: Excessive thermal grease thickness, warped heatsink, washer misalignment.
  Solution: Reinstall with a very thin, even thermal grease layer, verify heatsink flatness, and ensure full contact across the washer.

  2. Issue: Occasional breakdown during hi-pot testing.
  Possible causes: Contamination on the washer surface, damaged edges, or insufficient creepage distance in the design.
  Solution: Replace any chipped washers, clean surfaces carefully, and review clearance and creepage spacing in your layout.

  3. Issue: Cracked washers found after torque tightening.
  Possible causes: Over-tightened screws, uneven mounting surfaces, incorrect screw length causing local point loading.
  Solution: Follow device torque recommendation, ensure flat mounting surfaces, and use appropriate washers or spacers on the screw side if needed.

FAQ – Alumina Ceramic Washer for IC Package

1. Q: What is the main function of an alumina ceramic washer for an IC package?
   A: The alumina ceramic washer for the IC package provides electrical insulation between the power device and the heatsink while maintaining efficient heat conduction from the package to the cooling surface.
2. Q: How does alumina ceramic washer for an IC package compare with silicone pads?
   A: Alumina ceramic washer for IC package offers much higher thermal conductivity, typically in the 24–29 W/m·K range, while many silicone pads are in the single-digit W/m·K range, so it can lower device case temperature under the same mounting conditions.
3. Q: What thickness of alumina ceramic washer for IC package is commonly used?
   A: For TO-220, TO-247 and similar packages, alumina ceramic washers are often in the 0.3–1.0 mm thickness range, balancing dielectric strength, thermal resistance and mechanical strength.
4. Q: Which package types can use alumina ceramic washer for IC package?
   A: The washer is suitable for TO-220, TO-247, TO-218, TO-264, DO-4, DO-5 and other standard or custom IC packages used in power supplies, inverters and drivers.
5. Q: Can alumina ceramic washer for IC package be used with SiC or GaN devices?
   A: Yes, the high thermal conductivity, high insulation and high-temperature stability of alumina support the higher power density and junction temperature levels typically associated with SiC and GaN power devices.
6. Q: What is the maximum operating temperature for alumina ceramic washer for IC package?
   A: Alumina ceramic used in washers can typically operate continuously up to about 1500–1600 °C in air, which is well above normal case temperatures in power electronics.

Customer Reviews – Alumina Ceramic Washer for IC Package

• ⭐️⭐️⭐️⭐️⭐️
  We switched several TO-220 and TO-247 stages to an alumina ceramic washer for the IC package and saw a consistent reduction in case temperature during overload tests. The washers are dimensionally stable and fit our existing hole patterns without rework.
  -- Michael R., Power Electronics Engineer, DeltaDrive Systems (Germany)
• ⭐️⭐️⭐️⭐️⭐️
  ADCERAX supplied alumina ceramic washers for IC package with clear drawings and batch traceability. Pricing is competitive for the material grade and precision, and the dimensional consistency has simplified our incoming inspection.
  -- Susan T., Purchasing Manager, NorthWave Inverter Co. (USA)
• ⭐️⭐️⭐️⭐️⭐️
  For a new compact IGBT module we needed thin alumina ceramic washer for IC package with tight tolerances. The custom outline and slot design matched our layout, and the flatness supports our thermal performance targets.
  -- Kenji M., Development Manager, Sakura Power Modules (Japan)
• ⭐️⭐️⭐️⭐️⭐️
  We use alumina ceramic washer for IC package on several industrial drive platforms. Repeat orders from ADCERAX are delivered according to the agreed schedule, and the washers withstand our assembly torque and thermal cycling without chipping or cracking.
  -- Lucas B., Operations Director, EuroVolt Automation (Italy)