Power electronics module, electrical system comprising such a module, and corresponding manufacturing method - Patents.com

Abstract

- at least one electronic chip; and - a power electronics module (107) having an electrically insulating overmolded block (214) at least partially encapsulating each chip. The module (107) has at least one protrusion (218, 220) on which a component such as an electronic circuit board (208) for controlling each chip can rest, the protrusion (218, 220) comprising an electrically insulating material and extending from one surface (216a) of the block (214).

Description

[Technical field]

[0001] The invention relates to a power electronic module, to an electrical system comprising such a module and to a corresponding manufacturing method, the invention being particularly applicable in the automotive field. Summary of the Invention

[0002] 2. Description of the Related Art In many industrial applications, power electronics modules having electronic chips are employed to control electrical signals that govern the operation of electrical systems such as rotating electrical machines.

[0003] To protect the chips, it is known to place them at the bottom of a plastic casing and embed them in an electrically insulating gel poured into the casing. The side walls of the casing can then be provided with pads in which the fixing orifices are provided. A circuit board then supports these pads and can be fixed there by means of screws.

[0004] Such a solution has significant drawbacks, especially due to the use of a casing.

[0005] Alternatively, the chip can be protected by an overmold, for example made of epoxy resin, which forms a rigid block that encases the chip. In this case, the overmold block can be provided with a metal insert to allow the passage of screws for fastening the circuit board. The insert is, for example, overmolded at the same time as the chip and is flush with the face of the overmold block facing the circuit board.

[0006] In this solution, the circuit board is placed against the face of the overmolded block and fixed by screws threaded into the inserts, and the presence of the inserts constitutes an extra cost, but they are necessary to avoid that the screws could crack the overmolded block, compromising the protection of the chips.

[0007] Thus, there is no simple solution that allows for placement of the circuit board (or any other desired component) away from the overmolded block that encapsulates the chip.

[0008] It would therefore be desirable to provide a power electronics module that allows for alleviating at least some of the aforementioned problems and constraints.

[0009] So, what is proposed is, - at least one electronic chip; and - an electrically insulating overmolded block at least partially encapsulating each chip; A power electronics module having At least one protrusion, including an electrically insulating material and extending from one face of the block, is provided on which a component such as an electronic circuit board for controlling each chip can rest.

[0010] Thus, by means of one or more protrusions it is possible to keep the part away from the block without the need for a plastic casing. Furthermore, one or more of these protrusions may be used to fasten the part by screwing without the need for a metal insert, since the screw can be screwed into the material of the protrusion so that it does not reach the block, with very little risk of damaging the latter.

[0011] Optionally, the protrusion has a free end that defines a contact surface of the component.

[0012] Also optionally, the contact surface is planar.

[0013] Optionally, at least one protrusion is designed to secure the component in place.

[0014] Optionally, the contact surface of the protrusion designed to secure a component in place also has a threaded hole.

[0015] Also optionally, the threaded holes may be tapped or smooth and are intended to interface with thread-forming or self-tapping screws.

[0016] Optionally, the contact surface of the protrusion is also designed to allow the component to move away from the contact surface.

[0017] Also optionally, the contact surfaces of the protrusions designed to allow the parts to move apart do not have holes.

[0018] Also optionally, the protrusions have the form of cones and / or pyramids.

[0019] Also optionally, the protrusion and block are made integrally.

[0020] Also optionally, the protrusion and block are formed in two separate pieces.

[0021] Also optionally, it comprises a conductor, the projection being secured to the conductor.

[0022] Also optionally, the conductor has an aperture and the protrusion is secured to the conductor through the aperture.

[0023] Optionally, the projections are secured to the conductor by riveting or rivet-heading or overmolding.

[0024] Optionally, the block also encapsulates the base of the protrusion.

[0025] Also proposed is an electrical system comprising a module according to the invention and a component resting on each projection.

[0026] Also proposed is a method for manufacturing a module according to the invention, comprising the following steps: - Obtaining one or more chips; - overmolding the block over the chip, for example by transfer molding or by compression molding; and - Creating protrusions on which the parts can lean.

[0027] Optionally, the overmolding step is performed using a mold having a main molding cavity corresponding to the block and at least one sub-mold cavity corresponding respectively to one or more protrusions, the sub-cavities communicating with the main cavity such that each protrusion and the block are integral.

[0028] Also optionally, the manufacture of each protrusion is separate from the overmolding step, such that the protrusion or protrusions and the block are separate parts.

[0029] Also proposed is a method for manufacturing an electrical system according to the invention, comprising the following steps: - manufacturing a module according to the invention; - Using a machine tool, move the part against the face of the block until the part rests against each protrusion - using a machine tool to detect an increase in response to its movement; and - The use of machine tools to stop the movement of parts. [Brief description of the drawings]

[0030] The invention will be better understood from the following description, given by way of example only, with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 is a schematic diagram of an exemplary electrical system embodying the invention. [Diagram 2] FIG. 2 is a cross-sectional view of a power electronics module of the system of FIG. [Diagram 3] FIG. 3 is a perspective view illustrating a first example of the power electronics module of FIG. [Figure 4] FIG. 4 shows the module of FIG. 3 fitted with an electronic circuit board shown transparently to allow viewing of the remainder of the module. [Diagram 5] FIG. 5 is a block diagram illustrating steps of a method for manufacturing an electrical system having the module of FIGS. [Figure 6] FIG. 6 shows a further example of a power electronic module according to the invention in a partial perspective view. [Figure 7] FIG. 7 shows FIG. 6 with the module overmolded block removed. [Figure 8] FIG. 8 shows a view in cross section of the module of FIGS. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] An exemplary electrical system 100 embodying the invention will now be described with reference to Figure 1. The electrical system 100 is envisioned to be implemented, for example, in a motor vehicle (not shown).

[0032] The electrical system 100 first comprises a DC voltage source 102 having a positive pole and a negative pole, the latter being typically connected to an electrical ground such as the chassis of a motor vehicle. The DC voltage source 102 is arranged to provide an input voltage, denoted E.

[0033] The electrical system 100 further comprises a rotating electric machine 104 having a stator phase. In the illustrated example, the rotating electric machine 104 forms part of a starter alternator that is coupled to an internal combustion engine (not shown) of a motor vehicle. The rotating electric machine 104 is thus designed to operate alternately between a motor mode, in which it assists the internal combustion engine, and an alternator mode, in which it converts a portion of the mechanical energy produced by the internal combustion engine into electrical energy to recharge the DC voltage source 102.

[0034] The electrical system 100 further comprises a voltage converter 106 which is connected on the one hand to the terminals of the DC voltage source 102 and on the other hand to the rotating electrical machine 104 .

[0035] The voltage converter 106 has switching arms each associated with a stator phase. Each switching arm has a high-side switch connected to the positive terminal of the DC voltage source 102 and a low-side switch connected to the negative terminal of the DC voltage source 102. The high-side switch and the low-side switch are further connected to each other with a center tap connected to the associated stator phase.

[0036] Each switching arm is intended to be controlled to switch between two configurations: in a first configuration, called high-side configuration, the high-side switch is closed and the low-side switch is open, such that an input voltage E is applied to the associated stator phase; in a second configuration, called low-side configuration, the high-side switch is open and the low-side switch is closed, such that zero voltage is applied to the associated stator phase.

[0037] The electrical system further comprises power electronic modules 107 which respectively implement the switching arms.

[0038] The electrical system 100 further comprises a controller 108 for controlling the modules 107 to switch each arm between these two configurations. In the illustrated example, the voltage converter 106 is controlled in an inverter mode to supply electrical energy to the rotating electrical machine 104 when it is desired for the latter to operate in a motor mode. Furthermore, the voltage converter 106 is controlled in a rectification mode to supply electrical energy to (e.g. recharge) the DC voltage source 102 when it is desired for the rotating electrical machine 104 to operate in an alternator mode.

[0039] The switches are, for example, semiconductor switches having transistors, for example, metal oxide semiconductor field effect transistors (ie, MOSFETs) or insulated gate bipolar transistors (ie, IGBTs).

[0040] In the following description, various elements are given a spatial coordinate system according to an arbitrary orthogonal coordinate system having a vertical direction V, a longitudinal direction L, and a transverse direction T.

[0041] One of the modules 107 will now be described in more detail with reference to FIG. 2, although the other modules are similar.

[0042] The module 107 firstly comprises, in the example described, one or more electronic chips 201 each including one of the semiconductor switches of the switching arms of the voltage converter 106. In the example described, each chip 201 has two opposing electrical connection surfaces, one upper and one lower, and a control terminal.

[0043] The module 107 further comprises a substrate 202 on which the chips 201 are mounted. In the example described, the substrate 202 is made in two parts, each supporting one or more chips 201.

[0044] The substrate 202 is advantageously an electronic substrate such as, for example, a metal strip or plate or a printed circuit board comprising electrical tracks for electrically connecting the chips 201 to each other and / or to electrical conductors as described below. For example, the substrate 202 has a ceramic core coated with copper on one or two of its faces. It is for example a direct bond copper substrate, or DBC substrate. Alternatively, the substrate 202 may comprise a metal plate such as an aluminum plate covered with a dielectric layer, which is itself covered by a copper layer.

[0045] In particular, the underside of each chip 201 is electrically and / or mechanically coupled to the substrate 202, e.g. to at least one of its electrical tracks. Preferably, the underside of each electronic chip is simultaneously mechanically and electrically coupled to the substrate 202, preferably by brazing.

[0046] Module 107 also includes electrical conductors 204a-c, which are intended to be set at various electrical potentials, which are electrically connected to chip 201 according to a desired circuit to implement the switching arms in the illustrated example. Conductors 204a-c are configured to route electrical signals to or from at least a portion of chip 201.

[0047] The conductors 204a-c advantageously have substantially planar lead frames, which may comprise, for example, a metal, which are linearly extending and / or shaped, and which may optionally have bends and / or changes in the plane according to the desired topography.

[0048] The conductors 204a-c have connection ends 204'a-c for electrically or mechanically attaching the conductors 204a-c to the remainder of the voltage converter 106, for example to bus bars connecting the module 107 to the DC voltage source 102 and to the rotating electric machine 104.

[0049] In the described example, the conductors 204a-c include two conductors 204a, 204b and conductor 204c, with connection ends 204'a, 204'b of the two conductors 204a, 204b being connected to the positive and negative poles of the DC voltage source 102, respectively, and with connection end 204'c of the conductor 204c being connected to a respective one of the phases of the rotating electric machine 104.

[0050] Advantageously, each connection end 204'ac includes a through opening 307 (visible in Figures 3 and 4) to allow easy coupling, for example by screwing, via the through opening 307. Alternatively, the coupling can be made by brazing.

[0051] In the illustrated example, the top surface of each chip 201 is electrically and / or mechanically coupled to one of the conductors 204a-c, for example at the boss 206 of this conductor 204a-c. Preferably, the top surface of chip 201 is simultaneously mechanically and electrically coupled to the conductors 204a-c, preferably by brazing.

[0052] To mount the module on an electronic circuit board 208 (visible in FIG. 4) of the control device 108, the module 107 further comprises vertical pins 210 for electrically connecting the chip 201 and / or the substrate 202 and / or the conductors 204, respectively. These pins 210 have respective connection ends 210' for connecting to the circuit board 208. For example, these connection ends 210' are inserted into corresponding openings in the circuit board 208 and fixed to the latter by press-fitting or else by welding.

[0053] The electrical system 100 further preferably comprises a support 212 on which the modules 107 are mounted. This support 212 comprises, for example, a metal plate and is specifically designed to facilitate the dissipation of heat generated by the modules 107. In the example described, the support 212 is common to the three modules 107.

[0054] The module 107 further includes an overmolded block 214 that is electrically insulating and rigid and at least partially encapsulates each chip 201. Preferably, the block 214 completely encapsulates the chip or chips 201 of the module 107. The block 214 includes, for example, an epoxy resin. It is manufactured, for example, by a transfer molding technique or a compression molding technique.

[0055] For example, one or more chips 201 may be bare chips embedded in block 213 to create an encapsulation thereof. Block 214 advantageously encapsulates other components of module 107, as described below.

[0056] In this case, each block 214 of the module 107 has a substantially parallelepiped shape with two substantially parallel opposing large faces 216a, 216b, respectively the upper and lower faces, which are, for example, substantially rectangular.

[0057] Preferably, block 214 encapsulates not only chip 201 but also at least a portion of substrate 202, at least a portion of conductors 114 and / or at least a portion of pins 210. The rigidity of block 214 allows the encapsulation elements to be mechanically held together, thus achieving their encapsulation.

[0058] More specifically, in this case, block 214 encapsulates substrate 202 except for its underside, which is left free to contact support 212. Block 214 also encapsulates conductors 204a-c except for their connection ends 204'ac, and encapsulates pins 210 except for their connection ends 210'.

[0059] The module 107 further includes protrusions 218 , 220 comprising an electrically insulating material and extending from one side of the block 214 .

[0060] The block 214 and the protrusions 218, 220 are described in more detail with reference to FIGS.

[0061] The faces 216a, 216b are joined by a small side portion having longitudinal faces 302a, 302b and lateral faces 310a, 310b. The block 214 is substantially flat, i.e., the width and length of the faces 216a, 216b are much greater than the vertical distance separating them.

[0062] In the illustrated example, the connection ends 204'a-c of the conductors 204a-c project laterally beyond the block 214 by their lateral faces 310a, 310b. The connection end 210' of the terminal 210 projects laterally beyond the block 214 by its longitudinal faces 302a, 302b.

[0063] In the example described, the protrusions 218, 220 extend vertically upward from the upper surface 216a of the block 214. It should be noted that in the example described, they are arranged vertically side by side with the substrate 202. These protrusions 218, 220 have a height of, for example, 3 mm to 5 cm, measured from the larger upper surface 6a.

[0064] The protrusions 218 , 220 are designed in this case to receive the circuit board 208 in order to support it and keep it at a distance from the face 216 a of the block 214 facing the circuit board 208 .

[0065] The projections 218, 220 each have an upper free end which defines, for example, a contact surface 306, which is in particular a plane against which the circuit board 208 is designed to rest. Each contact surface 306 thus forms a bearing surface or end stop for the circuit board 208.

[0066] However, the protrusions 218 also have the function of making it possible to fasten the circuit board 222. To that end, they have a vertical screw hole 308 that leads into the contact surface 306, which is oriented along the vertical axis of the protrusion 218. This screw hole 308 is advantageously tapped or smooth to form a hole for screwing in a screw 402, intended to interact with a thread-forming screw or a self-tapping screw. Said screw passes, for example, through an orifice 404 that is correspondingly arranged on the circuit board 208.

[0067] In the illustrated example, four fixing protrusions 218 are provided located at the corners of the upper surface 216a of the block 214.

[0068] In contrast, the protrusion 220 does not have the function of fixing the circuit board 208, but only the function of providing a bearing surface or end stop for the circuit board 208. It is hereinafter referred to as the "bearing protrusion." Thus, the bearing protrusion 220 does not hold the circuit board 208, i.e., it allows the circuit board 208 to move upwardly away from the upper surface 216a of the block 214. For example, the contact surface 306 of the bearing protrusion 220 does not have a hole.

[0069] The bearing protrusion 220 is, for example, located substantially centrally on the upper surface 216 a and is preferably disposed equidistant from the fixing protrusion 218 .

[0070] Each of the protrusions 218, 220 (and in particular the bearing protrusion 220) can be configured to damp vibrations of the circuit board 208. Additionally, the location of each of the protrusions provided for damping purposes may depend on the configuration of the circuit board 208. In general, each of the protrusions provided for damping purposes is located at a vibration antinode of the circuit board 208.

[0071] To further limit vibration, stops may be provided on the opposite side of the circuit board 208 facing each protrusion provided for damping purposes.

[0072] Generally, module 107 includes at least one fixing protrusion, such as protrusion 218 , and / or at least one bearing protrusion, such as protrusion 220 .

[0073] Preferably, the fixing protrusions 218 and / or the bearing protrusions 220 have substantially the same height.

[0074] Each protrusion may in particular have the shape of a conical pyramid. This is the case, for example, for the fixing protrusion 218. Alternatively, each protrusion may have the shape of a truncated pyramid, in particular a truncated pyramid with a square base. This is the case, for example, for the bearing protrusion 220.

[0075] In a variant, the module 107 may only comprise one or more fixing protrusions. In another variant, the module 107 may only comprise one or more bearing protrusions.

[0076] According to one embodiment, at least one contact surface 306 is in direct contact with the underside of the circuit board 208. In a variant, a filler is interposed between this contact surface 306 and the circuit board 208, so that the circuit board 208 rests against the contact surface 306 via the filler. This filler is advantageously thermally conductive in order to allow the circulation of heat from the circuit board 208 to the block 214 in order to cool the electronic components (not shown) supported by the latter and / or the circuit board 208. For example, the filler may have a thermal conductivity of 1 to 5 Wm -1 K -1 It has a thermal conductivity of

[0077] According to the embodiment of Figures 2-4, each protrusion 218, 220 is integrally formed with the block 214. Thus, the block 214 and the one or more protrusions 218, 220 are integrally formed. This may be done in particular by providing a mold having a main mold cavity corresponding to the block 214 and at least one sub-mold cavity corresponding respectively to the one or more protrusions. To this end, each protrusion 218, 220 is made, for example, of epoxy resin, just like the block 214.

[0078] An exemplary method 500 for manufacturing an electrical system having a module 107, a support 212, and a circuit board 208 will be described with reference to FIG.

[0079] During step 502, an assembly of chip 201, substrate 202, conductors 204a-c and pins 210 is obtained.

[0080] During step 504, the assembly obtained is overmolded using a mold having a main molding cavity corresponding to block 214 and shapes corresponding to protrusions 218, 220 communicating with the main cavity. A single part is thus obtained by molding, this part having block 214 and protrusions 218, 220. Preferably, a transfer molding technique is used, otherwise a compression molding technique. Step 504 thus provides one of the modules 107. Steps 502, 504 are repeated to obtain the other modules 107.

[0081] During a step 506, the module 107 is fitted against the support 212 and fixed thereto.

[0082] During step 508, a machine tool is used to lower the circuit board 208 towards the upper surface 216a of the module 107. During this lowering movement, the pins 210 are inserted into corresponding openings 406 of the circuit board 208 (these openings are visible in FIG. 4). The pins 210 are, for example, press-fit, whereby their connection ends 210′ ​​have a larger diameter than the openings 406. These connection ends 210′ ​​are therefore radially compressed when they are being inserted, which requires a significant insertion force on the part of the machine tool.

[0083] During step 510, the circuit board 208 comes into contact with the protrusions 218, 220, which on the one hand allows the machine tool to control the vertical distance between the circuit board 208 and the module 107 by avoiding lowering the circuit board 208 too far, and on the other hand, this contact causes an increased reaction to the movement of the circuit board 208, which can be used as a signal to stop the movement.

[0084] Thus, during step 512, the machine tool detects an increased response to movement, thereby indicating that as much downward movement has been made to install the circuit board 208 as possible.

[0085] In response to detecting an increased reaction to the movement, the machine tool stops the movement of the circuit board 208 during step 514. It is thus possible to avoid the application of too much force when the circuit board 208 is mounted. A machine tool serving to mount the circuit board 208 in this sense advantageously comprises a stop on the other side of the circuit board 208, intended to face one or more bearing projections 220.

[0086] Another exemplary module 601 according to the invention will now be described.

[0087] 6 to 8, this module 601 is similar to module 107 of the preceding figures, except that it has at least one protrusion, indicated by reference numeral 602, which is a different part of block 214.

[0088] In the example described, one or more protrusions 602 replace the fixing protrusions 218 with their bearing and fixing functions retained. However, this variant can be applied to the bearing protrusions 220 as well.

[0089] As can be seen more specifically from Figures 7 and 8, the protrusion 602 is preferably fixed to one of the conductors 204a-c of the module 107. In the example described, it is arranged on the planar part 702 of the conductor 204c. Of course, the protrusion 602 can be fixed to one of the other conductors 204a, 204b. The protrusion 602 extends from the upper surface 704 of the planar part 702 to face the lower surface 706 facing the substrate 12. The protrusion 602 in this example is arranged near an edge 708 of the substrate 202 and / or near one of the connection ends 204'a-c of the conductors 204a-c.

[0090] 8, in order to fix the protrusions 602 in a defined position, the conductors 204a-c advantageously have openings 802 through which the protrusions 602 are fixed in a defined position by means of fastening elements 804, in particular by hot rivet heading or rivets. In this way, the lower surface of the protrusions 602 is kept leaning against the upper surface 704 of the planar part 702 of the conductor 204c, and the fastening elements 804, by passing through the openings 802, lean against the opposite lower surface 706. Any other method of fixation in a defined position is of course possible.

[0091] The protrusions 602 may be made in their illustrated form by an initial overmolding of the conductors 204c, either directly, or together with a subsequent rivet heading or rivet of the fastening elements 804 to give them their illustrated form, and the blocks 214 are then made, for example, after this initial overmolding and, if appropriate, after a rivet or rivet heading step.

[0092] The block 214 encapsulates the base 806 of the protrusion 602, i.e., the block 214 is overmolded onto the base 806. For example, the block 214 encapsulates the protrusion 602 over a height of a few tenths of a millimeter, for example 0.2 to 1.5 millimeters, from the upper surface 704 of the planar portion 702 of the conductor 204c. It will be appreciated that the protrusions 602 have sloping sidewalls, which allows the block 214 to cover them vertically, thus improving the fixation of the protrusions 602 in position.

[0093] An advantage of using two separate parts for the protrusion 602 and the block 214 is that it avoids cracks propagating between the protrusion 602 and the block 214 .

[0094] The protrusions 602 may be made of the same material as the blocks 214, in particular an epoxy resin.

[0095] In a variant, different materials are used, which has the advantage that materials can be used that are particularly suitable for producing threads intended for more standard screws and / or for vibration damping.

[0096] It should also be noted that the invention is not limited to the above-described embodiments, and indeed, it will be apparent to those skilled in the art that, in light of the teachings disclosed therein, various modifications can be made to the above-described embodiments.

[0097] In particular, the protrusions 218, 220, 602 may have a variety of shapes other than a frustoconical shape or a truncated pyramid. Additionally, they may have a variety of heights.

[0098] Additionally, each chip may include different types of components than semiconductor switches, such as: passive electronic components such as electrical resistors and / or capacitive components, and / or semiconductor chips for performing one or more logic functions to enable the power electronics module to format the power electronics signals.

[0099] Furthermore, the protrusions 218, 220, 602 may be designed to interact with any component other than an electronic circuit board, such as the circuit board 208, in particular with a framework for fastening the module. In this way, the protrusions 218, 220, 602 allow any component (the circuit board 208 or any other component) to be spaced apart from the face 216a of the block 214 without the need for additional parts.

[0100] Additionally, the system may be used in an air compressor, whereby a rotating electric machine 104 may be provided to drive an air compression element, particularly to generate the supply air flow for a motor.

[0101] In the above detailed description of the invention, the terms used should not be understood as limiting the invention to the embodiments disclosed herein, but should be understood as including all equivalents, the expectation of which is within the scope of those skilled in the art to apply their general knowledge just to the practice of the teachings disclosed therein.

Claims

1. A power electronics module (107; 601), At least one electronic chip (201); and an electrically insulating overmolded block (214) at least partially encapsulating each chip (201); It comprises at least one protrusion (218, 220, 602) against which components including an electronic circuit board (208) for controlling each chip (201) can rest, said protrusion (218, 220, 602) comprising an electrically insulating material and extending from one face (216a) of said block (214); The projection (218, 220, 602) has a free end that defines a contact surface (306) of the component. Power electronics module (107;601).

2. The module (107; 601) of claim 1, wherein the contact surface (306) is a flat surface.

3. 3. The module (107; 601) according to claim 1 or 2, wherein at least one protrusion (218, 602) is designed to fix the component in a fixed position.

4. The module (107; 601) according to any one of the preceding claims, wherein the contact surfaces (306) of the projections (218, 602) designed to fix the component in position have threaded holes (308).

5. 5. The module (107; 601) according to claim 4, wherein said screw holes (308) are tapped or smooth and are intended to interact with thread-forming or self-tapping screws.

6. 3. A module (107; 601) according to claim 1 or 2, wherein the contact surface (306) of the protrusion (218) is designed such that the component is allowed to move away from said contact surface (306).

7. 7. The module (107; 601) of claim 6, wherein the contact surfaces (306) of the protrusions (218, 602) designed to allow the components to move apart are free of holes.

8. The module (107; 601) according to any one of the preceding claims, wherein said protrusions (218, 220, 602) have the shape of a truncated cone and / or a truncated pyramid.

9. The module (107) of any one of the preceding claims, wherein said protrusions (218, 220) and said block (214) are integrally formed.

10. The module (601) of any one of claims 1 to 8, wherein the protrusion (602) and the block (214) are formed in two separate parts.

11. The module (601) of claim 10, comprising a conductor (204c), the protrusion (602) being secured to the conductor (204c).

12. 12. The module (601) of claim 11, wherein the conductor (204c) has an opening (802), and the protrusion (602) is fixed to the conductor (204c) through the opening (802).

13. The module (601) of claim 12, wherein the protrusions (602) are secured to the electrical conductors (204c) by rivets or rivet heading or overmolding.

14. The module (601) of any one of claims 10 to 13, wherein the block (214) encapsulates a base (806) of the protrusion (602).

15. An electrical system (100) comprising a module according to any one of the preceding claims and a component resting against each projection (218, 220, 602).

16. A method (500) for manufacturing a module (107; 601) according to any one of claims 1 to 14, comprising the following steps: Obtaining (502) the one or more chips (201); overmolding (504) the block (214) over the chip (201), for example by transfer molding or by compression molding; and manufacturing each protrusion (218, 220, 602) against which said component rests; The method (500) comprising:

17. 17. The method (500) of claim 16, wherein the overmolding step (504) is performed by using a mold having a main mold cavity corresponding to the block (214) and at least one sub-mold cavity corresponding to one or more protrusions (218, 220), respectively, the at least one sub-mold cavity communicating with the main mold cavity, thereby forming each protrusion (218, 220) and the block (214) integrally.

18. 17. The method of claim 16, wherein the manufacturing of each protrusion (602) is separate from the overmolding step (504), whereby the one or more protrusions (602) and the block (214) are separate pieces.

19. 20. A method (500) for manufacturing the electrical system (100) of claim 15, comprising the steps of: Manufacturing a module (107; 601) according to any one of claims 16 to 18; using a machine tool to move (508) the component toward the face (216a) of the block (214) until the component rests against each protrusion (218, 220, 602); Detecting an increase in response to the movement using the machine tool (512); and Stopping the movement of the component using the machine tool (514); The method (500) comprising:

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