Intra-cooling devices for power modules, methods for manufacturing same, power modules and electrical systems

A power module comprising:

• an intra-cooling device having a first opening on a top surface and a second opening on one of the top surface and a bottom surface;
• a top cap;
• a bottom cap coupled to the top cap, the bottom cap having a sidewall around an edge of the bottom cap, and the sidewall of the bottom cap has a sealing edge in contact with the top cap;
• a cavity between the top cap and the bottom cap;
• a first metal layer on an outer surface of the top cap;
• a second metal layer on an outer surface of the bottom cap;
• a plurality of first heat conductor fingers on the top cap and extending away from an inner surface of the top cap;
• and
• a plurality of second heat conductor fingers on the bottom cap and extending away from an inner surface of the bottom cap toward and between the plurality of first heat conductor fingers, a distance between the sidewall and a first one of the second heat conductor fingers is wider than a size of the first opening.

A method of manufacturing an intra-cooling device, comprising:

• forming a top cap having a plurality of first heat conductor fingers on an inner surface of the top cap and extending away from an inner surface of the top cap;
• forming a bottom cap having a plurality of second heat conductor fingers on an inner surface of the bottom cap and extending away from the inner surface of the bottom cap toward and between the plurality of first heat conductor fingers, wherein a sidewall surrounds an edge of the bottom cap, and wherein a first space between an end of the first heat conductor fingers and a surface of the bottom cap is wider than a thickness of one of the plurality of first heat conductor fingers;
• forming a first opening in one of the bottom cap and the top cap;
• forming a second opening in one of the bottom cap and the top cap;
• forming a cavity by assembling the top cap and the bottom cap to have the inner surface of the top cap and the inner surface of the bottom cap face each other.