Inductor module for power electronic assemblies and method for manufacturing the same

Abstract

The present disclosure relates to an inductor module for a power electronic assembly and a method of manufacturing the same. A method of manufacturing an inductor module includes providing an inductor including a conductor having a first end protruding from a first major face of a magnetic core and a second end protruding from a second major face of the magnetic core opposite the first major face; inserting the second end of the conductor into an opening of a metal clip, wherein the metal clip includes a base having the opening receiving the second end of the conductor and a first leg extending from the base along a first side face of the magnetic core; and deforming the second end such that the inductor is free to move along an axis parallel to the first leg of the metal clip with the second end of the conductor inserted into the opening of the metal clip.

Description

Technical Field

[0001] This disclosure relates to inductors, and more particularly to inductor modules for power electronic components and methods of manufacturing the same. Background Technology

[0002] The ever-increasing power demands of modern processors, coupled with the variability and decreasing trend of point-of-load voltage, have resulted in extremely high load currents, with peak currents reaching 1000 A or even higher becoming commonplace. Furthermore, the dynamic requirements of load jumps (especially sudden increases in load current) are extremely challenging. Since the ability of modern processors to perform additional computational tasks is primarily limited by thermal performance, precise regulation of the voltage at the processor's interface has become increasingly important. With processor power consumption essentially proportional to the square of the input voltage, reducing the input voltage to closer to the threshold of catastrophic processor failure allows the processor to operate at lower temperatures and handle additional computational tasks, making precise voltage regulation even more crucial.

[0003] When manufacturing power electronic components, such as voltage regulator modules used to regulate the voltage at the interface of a processor, complexities related to dimensional variations and limitations can arise. For example, dimensional variations resulting from manufacturing differences in the components of a power electronic component can make it difficult to achieve reliable connections between the corresponding parts. In some cases, these dimensional variations may prevent assembly from being completed, leading to an increased manufacturing scrap rate.

[0004] Therefore, a solution is needed that can accommodate the size variations of the components when forming power electronic components such as voltage regulator modules. Summary of the Invention

[0005] According to an embodiment of a method for manufacturing an inductor module, the method includes: providing an inductor including a conductor having a first end projecting from a first main surface of a magnetic core and a second end projecting from a second main surface of the magnetic core opposite to the first main surface; inserting the second end of the conductor into an opening of a metal clip, wherein the metal clip includes a base and a first leg, the base having an opening for receiving the second end of the conductor, and the first leg extending from the base along a first side surface of the magnetic core; and deforming the second end of the conductor when it is inserted into the opening of the metal clip, such that the inductor is freely movable along an axis parallel to the first leg of the metal clip, the movement of the inductor along the axis being constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core.

[0006] According to an embodiment of an inductor module, the inductor module includes: an inductor including a conductor having a first end projecting from a first main surface of a magnetic core and a second end projecting from a second main surface of the magnetic core opposite to the first main surface; and a metal clip including a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side surface of the magnetic core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed such that the inductor is freely movable along an axis parallel to the first leg of the metal clip, the movement of the inductor along the axis being constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core.

[0007] According to an embodiment of a method for manufacturing a power electronic component, the method includes: aligning one or more inductor modules with a circuit board, wherein each of the one or more inductor modules includes a metal clip and an inductor, wherein a conductor of the inductor has a first end projecting from a first main surface of a magnetic core of the inductor and a second end projecting from a second main surface of the magnetic core opposite to the first main surface, wherein the metal clip includes a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side surface of the magnetic core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed; attaching the first leg of the metal clip and the first end of the conductor to a circuit board or an assembly mounted on the circuit board, wherein during attachment, the inductor is freely movable along an axis parallel to the first leg of the metal clip, the movement of the inductor along the axis being constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core; and after attachment, securing the deformed second end of the conductor to the base of the metal clip.

[0008] According to an embodiment of a power electronic assembly, the power electronic assembly includes: one or more inductor modules, wherein each of the one or more inductor modules includes a metal clip and an inductor, wherein the conductor of the inductor has a first end projecting from a first main surface of the inductor core and a second end projecting from a second main surface of the core opposite to the first main surface, wherein the metal clip includes a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side surface of the core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed; and a circuit board, wherein the first leg of the metal clip and the first end of the conductor are attached to the circuit board or an assembly mounted on the circuit board, wherein the deformed second end of the conductor is fixed to the base of the metal clip and its width is greater than the opening of the metal clip.

[0009] Other features and advantages will be recognized by those skilled in the art upon reading the following detailed description and viewing the accompanying drawings. Attached Figure Description

[0010] The dimensions of the elements in the accompanying drawings are not necessarily drawn to scale. The same reference numerals denote corresponding and similar parts. Features of the various embodiments shown can be combined unless mutually exclusive. Embodiments are illustrated in the accompanying drawings and described in detail below.

[0011] Figure 1A-1D The illustration shows a view of an inductor module according to an embodiment.

[0012] Figure 2 The illustration shows a perspective view of an inductor and a metal clip according to an embodiment.

[0013] Figure 3 The illustration shows a perspective view of an inductor module during assembly according to an embodiment.

[0014] Figure 4 The illustration shows a method for aligning one or more inductor modules with a circuit board according to an embodiment.

[0015] Figure 5 The illustration shows a method for attaching one or more inductor modules to a circuit board according to an embodiment.

[0016] Figure 6 The illustration shows a method for securing the conductor of an inductor module to a metal clip of the inductor module according to an embodiment.

[0017] Figure 7 A cross-sectional side view of a power electronic component according to an embodiment is illustrated. Detailed Implementation

[0018] This document describes an inductor module with an inductor and a metal clip, assembled into a "rotating structure." This "rotating structure" allows the inductor module to accommodate dimensional deviations (e.g., caused by manufacturing variations) when assembled with another component. More specifically, utilizing an inductor module in a target application (such as power electronic components) may involve attaching each of the conductors and metal clips of the inductor module to a circuit board (such as a printed circuit board (PCB), embedded chip substrate, embedded die substrate, etc.) or a component of the circuit board. Factors such as manufacturing variations can cause the dimensions of the inductor module and / or the circuit board and / or the components of the circuit board to deviate from their design values. When using a standard inductor module, such dimensional deviations in the components can hinder successful attachment of the inductor module to the circuit board. In contrast, the "rotating structure" of the inductor module disclosed herein allows the inductor and the metal clip to move semi-independently relative to each other when the conductors and the metal clip are attached (e.g., soldered) to the corresponding components of the circuit board. This permissible relative movement between the inductor and the metal clip allows the inductor module to be successfully attached to the circuit board even when the dimensions (e.g., height) of one or more components to which the inductor module is attached, or even when the dimensions of the inductor module itself deviate from their design values. Therefore, attaching the inductor module to the circuit board may reduce the failure rate, potentially reducing manufacturing waste.

[0019] Next, exemplary embodiments of an inductor module, a method for forming an inductor module, a method for assembling an inductor module with other components to form a power electronic component, and a power electronic component including the inductor module will be described with reference to the accompanying drawings.

[0020] Figure 1A-1D The illustration shows a view of an inductor module 100 according to an embodiment. Figure 1A A cross-sectional side view of an inductor module 100 according to an embodiment is shown. Figure 1B A partial cross-sectional side view of an inductor module 100 according to an embodiment is shown. Figure 1C and 1D The illustration shows a perspective view of an inductor module 100 according to an embodiment.

[0021] The inductor module 100 includes an inductor 110 and a metal clip 140. The inductor 110 includes a conductor 120 partially embedded in a magnetic core 130. A first end 121 of the conductor 120 protrudes from a first main surface 131 of the magnetic core 130. A second end 122 of the conductor 120 protrudes from a second main surface 132 of the magnetic core 130 opposite to the first main surface 131.

[0022] The metal clip 140 includes a base 143. A first leg 141 of the metal clip 140 extends from the base 143 along a first side surface 133 of the magnetic core 130. A second leg 142 of the metal clip 140 extends from the base 143 along a second side surface 134 of the magnetic core 130 opposite to the first side surface 133. The first leg 141 and / or the second leg 142 may be oriented substantially perpendicular to the base 143. In this example, the metal clip 140 is U-shaped, covering the second main surface 132 of the magnetic core as well as the first side surface 133 and the second side surface 134.

[0023] The base 143 of the metal clip 140 has an opening 144 that receives the second end 122 of the conductor 120. The second end 122 of the conductor 120 extends through the opening 144 of the metal clip 140 and is deformed (e.g., deformed outward beyond the perimeter of the opening 144) such that the width of the deformed second end 122 of the conductor 120 is greater than the opening 144 of the metal clip 140 (e.g., wider in the x and / or y dimensions). 。 In this way, the deformed second end 122 of conductor 120 is confined through opening 144. Therefore, inductor 110 passes through the conductor 120 on the upper side 143 of base 143. US The deformed second end 122 and the lower side 143 of the base 143 LS The magnetic core 130 is fixed to the base 143 of the metal clip 140. In this example, the conductor 120 is deformed such that the second end 122 is received in a groove 145 formed on the upper surface 143 of the base 143. US In the middle, and coincides with opening 144 laterally.

[0024] Although the inductor 110 is fixed to the base 143 of the metal clip 140, the inductor can move freely along an axis 180 parallel to the first leg 141 of the metal clip 140 (e.g., as shown, parallel to...). z (Direction). The principle of inductor assembly 100 is in Figure 1B The figure in the middle shows that... Figure 1A An enlarged view of a portion of the inductor module 100 within the dashed window. The movement of the inductor 110 along axis 180 is constrained between a first position 151 defined by the deformed second end 122 of the conductor 120 and a second position 152 defined by the second main surface 132 of the magnetic core 130. That is, the inductor 110 can be in contact along axis 180 at the position where the deformed second end 122 contacts the metal clip 140 (e.g., the base of the groove 145) and at the position where the second main surface 132 of the magnetic core 130 contacts the metal clip 140 (e.g., the lower surface 143 of the base 143). LS It moves between the positions of contact.

[0025] like Figure 1C and1D As shown, the deformed second end 122 of conductor 120 may include a flange 123 that restricts movement of the deformed second end 122 through the opening 144 of the metal clip, thereby constraining movement of inductor 110 along axis 180 together with magnetic core 130. The flange 123 may have one or more features 125. Figure 1C and 1D In the example, feature 125 is implemented as a metal tab 125 formed in the deformed second end 122 of conductor 120 and bent outward beyond the perimeter of opening 144.

[0026] Figure 1D An embodiment of the inductor module 100 is illustrated, wherein the base 143 of the metal clip 140 includes one or more features 127 configured to engage a deformed second end 122 of the conductor 120 and restrict rotational movement of the inductor 110 about an axis 180. For example, features 127 may be formed in the base 143 of the metal clip 140 and configured to mate with one or more features 125 of the flange 123 of the conductor 120. Figure 1D An example is illustrated where the feature 127 formed in the base 143 is implemented as a corresponding notch 127, each notch being sized to receive a metal tab 125 of the flange 123. In this example, the notch 127 is formed on the upper surface 143 of the base 143. US The groove 145 in the base 143 is merged. An example is also envisioned in which feature 127 is formed in the opening 144 of the base 143 (e.g., along the perimeter of the opening 144).

[0027] Figure 1A-1DThe inductor module 100 illustrated in the embodiments can be characterized as a “rotating structure” formed by engaging an inductor 110 (more specifically, the second end 122 of the conductor) with a metal clip 140. In this “rotating structure” arrangement, the inductor 110 is fixed to the metal clip 140 but can be moved in a restricted manner along axis 180 (e.g., within constraints defined by the deformed second end 122 of the conductor 120 and the magnetic core 130) and can rotate freely or in a restricted manner about axis 180. As will be further discussed in subsequent embodiments, utilizing the inductor module 100 in a target application (e.g., power electronic components) may include connecting each of the conductor 120 and the metal clip 140 to components (e.g., metallization layers, terminals, nodes, pads, chips, etc.) of a circuit board (such as a printed circuit board (PCB), embedded chip substrate, embedded die substrate, etc.). This attachment may include attaching each of the conductor 120 and the first and / or second legs 141 and 142 of the metal clip 140 to a corresponding component of the circuit board by soldering or other means. The "rotating structure" of the inductor module 100 allows the inductor 110 and the metal clip 140 (e.g., the first and / or second legs 141 and 142) to the corresponding component of the circuit board while the conductor 120 and the metal clip 140 are attached (e.g., soldered) to the corresponding component. This allowed relative movement allows the inductor module 100 to accommodate deviations in the design height of the corresponding component to which the conductor 120 and the metal clip 140 are attached. Therefore, the failure rate of attaching the inductor module 100 to the component may be reduced, potentially reducing manufacturing scrap.

[0028] Figure 2 The illustration shows a perspective view of the inductor 110 and the metal clip 140 according to an embodiment. The inductor 110 and the metal clip 140 can be as follows... Figure 2 The inductor 110 is shown in an unassembled state for assembly of the inductor module 100. The magnetic core 130 of the inductor 110 can be formed of a suitable magnetic material, such as a ferromagnetic material like iron. The conductor 120 of the inductor 110 can be formed of any suitable metal or other conductive material. The conductor 120 can have a conductor axis 120... A An extended cylindrical or cuboid shape. The metal clip 140 can be formed of copper and / or any other metal or metal alloy. For example, by stamping, bending, etc., the first leg 141, the second leg 142, and the base 143 of the metal clip 140 can be formed as a single continuous unit. Although Figure 2 Not specifically shown, but the metal clip 140 may have one or more features formed in the base 143 (e.g., Figure 1D Features 127) are configured to restrict rotational movement of the inductor 110 about axis 180 when the inductor 110 is assembled with the metal clip 140.

[0029] When inductor 110 is formed and supplied, the second end 122 of its conductor 120 is in an undeformed state. Figure 2 In this example, conductor 120 forms and provides a flange 123 with a metal tab 125 disposed at a second end 122. In this example, the undeformed state of the second end 122 is characterized in that the metal tab 125 of the flange 123 is substantially parallel to the conductor axis 120. A Oriented, rather than like Figure 1A-1D As shown in the assembled inductor module 100, it bends outward beyond the perimeter of the opening 144.

[0030] Figure 3 The illustration shows a perspective view of the inductor module 100 during assembly according to an embodiment. The inductor 110 and the metal clip 140 can be assembled by inserting the undeformed second end 122 of the conductor 120 into the opening 144 of the metal clip 140 to form... Figure 3 The inductor module 100 is partially assembled. When the inductor 110 and the metal clip 140 are assembled in this manner, the conductor axis 120... A It can be substantially aligned with axis 180. After inserting the undeformed second end 122 of conductor 120 into the opening 144 of metal clip, inductor 110 can be secured to base 143 of metal clip 140 by deforming the second end 122 (e.g., bending the metal tab 125 of the flange outward) to form Figure 1A-1D The deformed second end 122 is shown. Deforming the second end 122 of the conductor 120 may include stamping the second end 122 of the conductor 120 (e.g., stamping a flange 123 to bend the metal tab 125 outward beyond the perimeter of the opening 144).

[0031] Figure 4-6 The illustration depicts a method of assembling an inductor module 100 with other components to form a power electronics assembly 10. An embodiment of the completed power electronics assembly 10 is shown in... Figure 6 and Figure 7 As shown in the figure. The power electronics component 10 may be, for example, a voltage regulator module (e.g., a DC-DC converter, such as a buck converter), which is configured to receive an input voltage (e.g., from a power source) and deliver a point-of-load voltage to a processor or other load.

[0032] Figure 4 The illustration shows a method for aligning one or more inductor modules 100 with a circuit board 160 according to an embodiment. Although Figure 4The illustration shows an inductor module 100 with individual metal clips 140, but examples of inductor modules 100 including two or more inductors 110 fixed to a common metal clip 140 are also envisioned. The circuit board 160 may be a PCB, an embedded chip substrate, an embedded die substrate, etc. The circuit board 160 includes multiple components 161. Components 161 may include one or more metallization layers, metal traces, nodes, terminals, contact pads, vias, interconnects, substrates, passive components (e.g., capacitors, resistors), active components (e.g., transistor dies, such as MOSFETs, BJTs, and / or IGBT dies), surface-mount dies and / or chips, embedded dies and / or chips, drivers, controllers, sensing elements, heat sinks, etc. The multiple components 161 may be arranged to form all or part of a circuit, such as a power stage, a DC / AC inverter, a DC / DC converter, an AC / DC converter, a DC / AC converter, an AC / AC converter, a multiphase inverter, an H-bridge, a motor driver, etc. Each inductor 110 and metal clip 140 (e.g., first and second legs 141 and 142 of each metal clip 140) can be aligned with one or more components 161 of the circuit board 160 for subsequent attachment to the corresponding component(s) 161. The alignment of the inductor module(s) 100 with the circuit board 160 and their subsequent placement on the circuit board 160 for attachment can be accomplished by pick-and-place tools or other means.

[0033] Figure 5 The illustration depicts a method of attaching one or more inductor modules 100 to a circuit board 160 according to an embodiment. Each of the inductor 110 and the metal clip 140 may be attached (e.g., by soldering or other means (e.g., conductive adhesive)) to one or more components 161 of the circuit board 160. The first end 121 of the conductor 120 ( Figure 5 (Not shown) can be attached (e.g., soldered) to a switching node of a power stage formed by a plurality of components 161 of circuit board 160. For example, the switching node can be a node between the high-side transistor and the low-side transistor of a half-bridge inverter. The first leg 141 or the second leg 142 of the metal clip 140 can be attached (e.g., soldered) to a power output node of the circuit board. The first leg 141 or the second leg 142 of the metal clip 140 can be attached (e.g., soldered) to a metallization layer (e.g., a metal island) of circuit board 160.

[0034] During the process of attaching the inductor module(s) 100 to the circuit board 160, each inductor 110 is freely movable along axis 180. The inductor 110 is movable along axis 180 and, in some cases, can rotate about axis 180. Moving the inductor 110 relative to the metal clip 140 during attachment of the inductor module 100 to the circuit board 160 allows the attachment of the inductor module 100 to be completed even when the dimensions (e.g., height) of one or more components 161 to which the inductor module 100 is attached, or even the dimensions of the inductor module 100 itself, deviate from their design values. Such deviations from design dimensions may stem from manufacturing variations, and by utilizing the inductor module 100 of this disclosure when forming the power electronic assembly 10, the process of attaching the inductor module(s) 100 to the circuit board 160 can be adapted to such manufacturing variations while still successfully attaching the inductor module(s) 100, potentially reducing manufacturing waste.

[0035] Figure 6 The illustration depicts a method for securing the conductor 110 of an inductor module 100 to a metal clip 140 according to an embodiment. This is done after attaching the inductor module(s) 100 to a circuit board 160 (e.g., as shown in the diagram). Figure 5 As shown, the deformed second end 122 of the conductor 120 of each inductor 110 is fixed to the base 143 of the metal clip 140. Fixing the conductor 120 to the base 143 may include securing the deformed second end 122 of the conductor 120 to the base 143 using a fastening element 170. The fastening element 170 may be, for example, solder, adhesive, encapsulant, fastener, clip, etc. At this point, the assembly of (multiple) inductor modules 100 and circuit board 160 and its components 161 constitutes the power electronic assembly 10.

[0036] Figure 7 A cross-sectional side view of the power electronics assembly 10 according to an embodiment is shown. Figure 7 The power electronics component 10 may be a voltage regulator module (e.g., a DC-DC converter, such as a buck converter) configured to receive an input voltage (e.g., from a power source) and deliver a point-of-load voltage to a processor or other load.

[0037] A first end 121 of conductor 120 is attached (e.g., soldered, brazed, sintered, etc.) to a first component 1611 of circuit board 160. Inductor 110 and first component 1611 may form a power stage of power electronic assembly 10. First component 1611 may, for example, include one or more power switches (e.g., MOSFETs) attached or embedded in the substrate and at switching node 161. SW The two power switches of the first component 1611 are connected in series. For example, the two power switches of the first component 1611 can be connected in series at the switching node 161. SWThe circuit is configured in a half-bridge configuration, where the first power switch is a high-side switch acting as a control switch, and the second switch is a low-side switch acting as a synchronous rectifier switch. This circuit can form a synchronous buck converter that receives input voltage from the input power terminal (e.g., formed in circuit board 160) and at switching node 161... SW The conductor 120 is coupled to inductor 110. The first end 121 of conductor 120 can be attached to the switching node 161 of the first component 1611. SW The second leg 142 of the metal clip 140 is attached (e.g., soldered, brazed, sintered, etc.) to a second component 1612 of the circuit board 160. This second component can be electrically coupled to a power output terminal, or it can itself form a power output terminal of the power electronics component 10. Therefore, the power stage can receive an input voltage from the power input terminal and at the switching node 161... SW Phase current is output to conductor 120. The current can flow through conductor 120, fastening element 170, metal clip 140 and second part 1612 of circuit board 160, and power electronics 10 can supply power to the load from power output terminal.

[0038] Although this disclosure is not limited thereto, the examples numbered below illustrate one or more aspects of this disclosure.

[0039] Example 1. A method of manufacturing an inductor module, the method comprising: providing an inductor including a conductor having a first end projecting from a first main surface of a magnetic core and a second end projecting from a second main surface of the magnetic core opposite to the first main surface; inserting the second end of the conductor into an opening of a metal clip, wherein the metal clip includes a base and a first leg having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side surface of the magnetic core; and deforming the second end of the conductor, such that the inductor is freely movable along an axis parallel to the first leg of the metal clip, wherein the movement of the inductor along the axis is constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core.

[0040] Example 2. The method according to Example 1 further includes: limiting rotational movement of the inductor about the axis, wherein limiting rotational movement of the inductor about the axis includes: forming a flange disposed at a deformed second end of the conductor, the flange having one or more features; and forming one or more features in the base of the metal clip, the one or more features being configured to engage with one or more features of the flange.

[0041] Example 3. According to the method of Example 1 or 2, the base of the metal clip includes one or more features configured to engage a deformed second end of the conductor and restrict rotational movement of the inductor about the axis.

[0042] Example 4. The method according to any one of Examples 1 to 3, wherein deforming the second end of the conductor includes stamping the second end of the conductor.

[0043] Example 5. The method according to any one of Examples 1 to 4 further includes: forming one or more features in the base of the metal clip, wherein the one or more features are configured to restrict rotational movement of the inductor about the axis.

[0044] Example 6. An inductor module comprising: an inductor including a conductor having a first end projecting from a first main surface of a magnetic core and a second end projecting from a second main surface of the magnetic core opposite to the first main surface; and a metal clip including a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side surface of the magnetic core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed such that the inductor is freely movable along an axis parallel to the first leg of the metal clip, the movement of the inductor along the axis being constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core.

[0045] Example 7. An inductor module according to Example 6, wherein the deformed second end of the conductor includes a flange having one or more features, and wherein the base of the metal clip includes one or more features, the one or more features of the base of the metal clip being configured to engage with one or more features of the flange and restrict rotational movement of the inductor about the axis.

[0046] Example 8. An inductor module according to Example 7, wherein one or more features of the flange include at least one metal tab formed in a deformed second end of the conductor, and wherein one or more features of the metal clip base include a corresponding notch sized to receive each metal tab of the flange.

[0047] Example 9. An inductor module according to any one of Examples 6 to 8, wherein the base of the metal clip includes one or more features configured to engage a deformed second end of the conductor and restrict rotational movement of the inductor about the axis.

[0048] Example 10. An inductor module according to any one of Examples 6 to 9, wherein the metal clip further includes a second leg extending from the base along a second side of the magnetic core opposite to the first side.

[0049] Example 11. A method of manufacturing a power electronic component, the method comprising: aligning one or more inductor modules with a circuit board, wherein each of the one or more inductor modules includes a metal clip and an inductor, wherein a conductor of the inductor has a first end projecting from a first main face of a magnetic core of the inductor and a second end projecting from a second main face of the magnetic core opposite to the first main face, wherein the metal clip includes a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side face of the magnetic core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed; attaching the first leg of the metal clip and the first end of the conductor to a circuit board or a component mounted on the circuit board, wherein during attachment, the inductor is freely movable along an axis parallel to the first leg of the metal clip, the movement of the inductor along the axis being constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main face of the magnetic core; and after attachment, securing the deformed second end of the conductor to the base of the metal clip.

[0050] Example 12. According to the method of Example 11, the metal clip further includes a second leg extending from the base along a second side of the magnetic core opposite to the first side, and the attachment further includes attaching the second leg of the metal clip to a circuit board or a component mounted on the circuit board.

[0051] Example 13. According to the method of Example 11 or 12, the fixing includes: using a fastening element to fasten the deformed second end of the conductor to the base.

[0052] Example 14. According to the method of Example 13, the fastening element is selected from the group consisting of solder, adhesive, encapsulant and fastener.

[0053] Example 15. The method according to any one of Examples 11 to 14 further includes: moving the inductor along the axis during attachment.

[0054] Example 16. The method according to any one of Examples 11 to 15 further includes: rotating the inductor about an axis during attachment.

[0055] Example 17. A power electronic component comprising: one or more inductor modules, wherein each of the one or more inductor modules includes a metal clip and an inductor, wherein a conductor of the inductor has a first end projecting from a first main face of a magnetic core of the inductor and a second end projecting from a second main face of the magnetic core opposite to the first main face, wherein the metal clip includes a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side face of the magnetic core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed; and a circuit board, wherein the first leg of the metal clip and the first end of the conductor are attached to the circuit board or a component mounted on the circuit board, wherein the deformed second end of the conductor is fixed to the base of the metal clip and is wider than the opening of the metal clip.

[0056] Example 18. A power electronic assembly according to Example 17, wherein the metal clip further includes a second leg extending from the base along a second side of the magnetic core opposite to the first side, and wherein the second leg of the metal clip is attached to a circuit board or a component mounted on the circuit board.

[0057] Example 19. The power electronic assembly according to Example 17 or 18 further includes: wherein the deformed second end of the conductor is secured to the base of the metal clip by a fastening element.

[0058] Example 20. A power electronic assembly according to Example 19, wherein the fastening elements are selected from the group consisting of solder, adhesive, encapsulant and fasteners.

[0059] Example 21. A power electronic assembly according to any one of Examples 17 to 20, wherein the deformed second end of the conductor includes a flange having one or more features, and wherein the base of the metal clip includes one or more features configured to engage with one or more features of the flange and restrict rotational movement of the inductor about an axis parallel to a first leg of the metal clip.

[0060] Example 22. A power electronic assembly according to any one of Examples 17 to 21, wherein the base of the metal clip includes one or more features configured to engage a deformed second end of a conductor and restrict rotational movement of the inductor about an axis.

[0061] Terms such as "first" and "second" are used to describe various components, areas, parts, etc., and are not intended to be limiting. Similar terms refer to similar components throughout the specification.

[0062] As used herein, the terms “having,” “containing,” “including,” “comprising,” etc., are open-ended terms indicating the presence of the stated element or feature, but not excluding additional elements or features. The articles “a,” “an,” and “the” are intended to include both singular and plural forms unless the context clearly indicates otherwise.

[0063] The expression “and / or” should be interpreted to include all possible combinations of conjunctions and disjunctive words, unless otherwise expressly stated. For example, “A and / or B” should be interpreted to mean A but not B, B but not A, or both A and B. The expression “at least one” should be interpreted in the same way as “and / or”, unless otherwise expressly stated. For example, “at least one of A and B” should be interpreted to mean A but not B, B but not A, or both A and B.

[0064] It should be understood that, unless otherwise specified, the features of the various embodiments described herein can be combined with each other.

[0065] Although specific embodiments have been illustrated and described herein, those skilled in the art will understand that various alternatives and / or equivalent implementations can be used to replace the illustrated and described specific embodiments without departing from the scope of the invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that the invention be limited only by the claims and their equivalents.

Claims

1. A method for manufacturing an inductor module, the method comprising: An inductor is provided, the inductor including a conductor having a first end projecting from a first main surface of a magnetic core and a second end projecting from a second main surface of the magnetic core opposite to the first main surface; The second end of the conductor is inserted into the opening of a metal clip, wherein the metal clip includes a base and a first leg, the base having the opening for receiving the second end of the conductor, and the first leg extending from the base along a first side of the magnetic core; as well as When the second end of the conductor is inserted into the opening of the metal clip, the second end is deformed, causing the inductor to move freely along an axis parallel to the first leg of the metal clip, wherein the movement of the inductor along the axis is constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core.

2. The method according to claim 1, further comprising: Restricting the rotational movement of the inductor about the axis, The restriction on the rotational movement of the inductor about the axis includes: A flange is formed at the deformed second end of the conductor, the flange having one or more features; and One or more features are formed in the base of the metal clip, the one or more features being configured to mate with one or more features of the flange.

3. The method of claim 1, wherein the base of the metal clip includes one or more features configured to engage the deformed second end of the conductor and restrict rotational movement of the inductor about the axis.

4. The method of claim 1, wherein deforming the second end of the conductor comprises stamping the second end of the conductor.

5. The method according to claim 1, further comprising: One or more features are formed in the base of the metal clip, wherein the one or more features are configured to restrict the rotational movement of the inductor about the axis.

6. An inductor module, comprising: An inductor, the inductor including a conductor having a first end projecting from a first main surface of a magnetic core and a second end projecting from a second main surface of the magnetic core opposite to the first main surface; as well as A metal clip includes a base and a first leg, the base having an opening for receiving a second end of the conductor, and the first leg extending from the base along a first side surface of the magnetic core. The second end of the conductor extends through the opening of the metal clip and is deformed such that the inductor moves freely along an axis parallel to the first leg of the metal clip, wherein the movement of the inductor along the axis is constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core.

7. The inductor module of claim 6, wherein the deformed second end of the conductor includes a flange having one or more features, and wherein the base of the metal clip includes one or more features, the one or more features of the base of the metal clip being configured to engage with the one or more features of the flange and restrict rotational movement of the inductor about the axis.

8. The inductor module of claim 7, wherein the one or more features of the flange include at least one metal tab formed in the deformed second end of the conductor, and wherein the one or more features of the base of the metal clip include a corresponding notch sized to receive each metal tab of the flange.

9. The inductor module of claim 6, wherein the base of the metal clip includes one or more features configured to engage the deformed second end of the conductor and restrict rotational movement of the inductor about the axis.

10. The inductor module of claim 6, wherein the metal clip further comprises a second leg extending from the base along a second side of the magnetic core opposite to the first side.

11. A method for manufacturing a power electronic component, the method comprising: Align one or more inductor modules with a circuit board, wherein each of the one or more inductor modules includes a metal clip and an inductor, wherein the conductor of the inductor has a first end protruding from a first main surface of the inductor core and a second end protruding from a second main surface of the core opposite to the first main surface, wherein the metal clip includes a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side surface of the core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed; Attaching the first leg of the metal clip and the first end of the conductor to the circuit board or a component mounted on the circuit board, wherein during attachment, the inductor moves freely along an axis parallel to the first leg of the metal clip, wherein the movement of the inductor along the axis is constrained between a first position defined by the deformed second end of the conductor and a second position defined by the second main surface of the magnetic core; and After the attachment, the deformed second end of the conductor is secured to the base of the metal clip.

12. The method of claim 11, wherein the metal clip further comprises a second leg extending from the base along a second side of the magnetic core opposite to the first side, and wherein the attachment further comprises: The second leg of the metal clip is attached to the circuit board or a component mounted on the circuit board.

13. The method of claim 11, wherein the fixing comprises: The deformed second end of the conductor is secured to the base using fastening elements.

14. The method of claim 13, wherein the fastening element is selected from the group consisting of solder, adhesive, encapsulant, and fastener.

15. The method of claim 11, further comprising: During the attachment, the inductor is moved along the axis.

16. The method of claim 11, further comprising: During the attachment, the inductor is rotated about the axis.

17. A power electronic component, comprising: One or more inductor modules, wherein each of the one or more inductor modules includes a metal clip and an inductor, wherein the conductor of the inductor has a first end protruding from a first main surface of the inductor core and a second end protruding from a second main surface of the core opposite to the first main surface, wherein the metal clip includes a base and a first leg, the base having an opening for receiving the second end of the conductor, the first leg extending from the base along a first side surface of the core, wherein the second end of the conductor extends through the opening of the metal clip and is deformed; as well as A circuit board, wherein the first leg of the metal clip and the first end of the conductor are attached to the circuit board or a component mounted on the circuit board. The second end of the deformed conductor is fixed to the base of the metal clip and is wider than the opening of the metal clip.

18. The power electronic assembly of claim 17, wherein the metal clip further comprises a second leg extending from the base along a second side of the magnetic core opposite to the first side, and wherein the second leg of the metal clip is attached to the circuit board or a component mounted on the circuit board.

19. The power electronic component of claim 17, further comprising: The second end of the deformed conductor is secured to the base of the metal clip by a fastening element.

20. The power electronic assembly of claim 19, wherein the fastening element is selected from the group consisting of solder, adhesive, encapsulant, and fastener.

21. The power electronic assembly of claim 17, wherein the deformed second end of the conductor includes a flange having one or more features, and wherein the base of the metal clip includes one or more features, the one or more features of the base of the metal clip being configured to engage with the one or more features of the flange and restrict rotational movement of the inductor about an axis parallel to the first leg of the metal clip.

22. The power electronic assembly of claim 17, wherein the base of the metal clip includes one or more features configured to engage with the deformed second end of the conductor and restrict rotational movement of the inductor about the axis.

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