Embedded Power Module Heat Dissipation and Testing
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Solution Overview
Problem
Conventional circuit board structures lack efficient heat dissipation for high-power chips and cannot individually test power chips, leading to defects that render the entire board unusable if a power chip is faulty.
Innovation Solution
A circuit board structure with an electrically and thermally conductive carrier that allows for individual testing of power chips, featuring an insulating material with power units and a circuit layer connected to the conductive carrier, enabling rapid heat and electrical energy transmission and isolation from external interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power chips are embedded in conventional circuit board structure, then power supplying efficiency is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The invention segments the circuit board into multiple layers with dedicated heat dissipation pathways. The conductive lines are distributed across different layers (first conductive lines in signal layer, second conductive lines in ground layer) to create separate heat dissipation channels, allowing heat from power chips to be efficiently conducted away through multiple paths rather than a single congested pathway.
Solution Approach 2:
The invention employs composite material structures combining different conductive materials with varying thermal and electrical properties. The first and second conductive lines use different metal compositions or cross-sectional areas to optimize both electrical conductivity for power supply and thermal conductivity for heat dissipation, creating a multi-functional conductive system.
2Volume of moving object
If power chips are embedded in conventional circuit board structure, then device size is reduced, but testing capability deteriorates
Solution Approach 1:
The invention implements preliminary testing actions by providing dedicated test conductive lines that are pre-configured to access specific functional regions of the power chip (power supply region, signal processing region, heat dissipation region). These test pathways are established during board fabrication, enabling individual chip testing to be performed before final assembly, thus identifying defects early without requiring device disassembly.
Solution Approach 2:
The invention introduces intermediary test conductive lines as mediators between the embedded power chip and external testing equipment. These dedicated test lines act as intermediaries that provide access to internal chip regions without disrupting the compact embedded structure, allowing testing signals to reach otherwise inaccessible areas of the power chip.
3Ease of manufacture
If conductive lines are formed without considering heat dissipation, then manufacturing simplicity is improved, but heat dissipation efficiency deteriorates
Solution Approach 1:
The invention makes the conductive lines universal by designing them to serve multiple functions simultaneously. The first and second conductive lines are configured to provide both electrical connectivity (power supply and signal transmission) and thermal management (heat dissipation). This multi-functionality is achieved through strategic placement, varying cross-sectional areas, and selecting materials that satisfy both electrical and thermal requirements, eliminating the need for separate dedicated heat dissipation structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures that power chips can be tested for defects before embedding, preventing defective modules from being integrated into the circuit board and enhancing heat dissipation, thus improving the reliability and efficiency of the circuit board.
Implementation Method 1
an electrically and thermally conductive carrier having a transmitting portion and a carrying portion perpendicularly connected to the transmitting portion... the power chips are configured to be individually tested through the circuit layer and the electrically and thermally conductive carrier... transmitting heat-energy and electrical-energy at the same time
Implementation Method 2
an electrically and thermally conductive carrier having a transmitting portion and a carrying portion perpendicularly connected to the transmitting portion... the first electrode layers are fixed on and electrically connected to the carrying portion in parallel... transmitting heat-energy and electrical-energy at the same time
Implementation Method 3
an insulating material having a first surface and an opposite second surface... the power unit is at least partially covered by the insulating material... isolating an external interference
Data Source
AI summary
A circuit board structure with chips embedded therein includes a multi-layer board and a power module embedded in the multi-layer board. The power module includes an insulating material, a power unit covered by the insulating material, and a circuit layer disposed on the insulating material. The power unit includes an electrically and thermally conductive carrier and a plurality of power chips. The electrically and thermally conductive carrier includes a transmitting portion and a carrying portion perpendicularly connected to the transmitting portion. Each power chip has a first electrode layer and an opposite second electrode layer. The first electrode layers are fixed on and electrically connected to the carrying portion in parallel, and the power chips are disposed at one side of the transmitting portion. The circuit layer is electrically connected to the electrically and thermally conductive carrier and the second electrode layers.


