High-voltage power modules in converter equipment are subjected to long-term combined stresses

including high electric fields

high temperatures

and high dU/dt

making packaging insulation failure a critical issue for reliable operation. This paper reviews the failure mechanisms and coordinated regulation of electro-thermal performance in silicone-gel packaging insulation and its gel-solid interfaces

as well as electro-thermal coordinated regulation. The typical packaging structures of high-voltage power modules and insulation condition sensing methods are summarized. Then

the material properties and initial insulation state of silicone-gel packaging insulation are reviewed

followed by an analysis of high-temperature degradation and interfacial deterioration

as well as the aging-induced evolution of the electrical

thermal

and mechanical properties of insulating materials. The development mechanisms of partial discharge

gel-solid interfacial discharge

and electrical treeing under coupled multi-stress conditions are further discussed. On this basis

recent advances in local electric-field regulation

thermal-conductivity enhancement

and electro-thermal performance optimization are comparatively analyzed. Finally

future research directions are proposed in terms of quantitative failure-path modeling

multi-parameter condition sensing and lifetime assessment

electro-thermal coordinated design

and evaluation under realistic service conditions. This review provides reference for understanding insulation failure mechanisms

optimizing packaging materials

and improving the reliability design of packaging insulation in high-voltage power modules.