Integrated Hall-Sensing Power Module With Eddy Current Segmentation

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Solution Overview

Problem

Existing power modules face challenges in current sensing accuracy due to external current sensors increasing size and internal interference from eddy currents, which affect the stability and efficiency of the power conversion system.

Innovation Solution

Incorporating a Hall element within the power module with an eddy current reduction pattern that divides the metal conductive part into segments, electrically isolating the sensor part and reducing eddy currents to improve sensing accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a current sensor is provided outside the power module, then current sensing is enabled, but the overall size increases

Engineering Contradiction:

Improvecurrent sensing capabilityVSAvoidpower module size

Core Design Contradiction:

Measurement precisionVSVolume of stationary object

Solution Approach 1:

The current sensor (Hall element) is integrated within the power module by mounting it on the substrate, merging the sensing function with the power module structure. This eliminates the need for external current sensors and reduces the overall system size while maintaining current sensing capability.

Inventive Principle:

Principle #5Merging (Combining)

2Volume of stationary object

If a Hall element is provided inside the power module, then the volume is reduced, but sensing accuracy is reduced due to eddy currents

Engineering Contradiction:

Improvepower module sizeVSAvoidsensing accuracy

Core Design Contradiction:

Volume of stationary objectVSMeasurement precision

Solution Approach 1:

The metal conductive part is divided into multiple segments with the Hall element positioned in a gap between segments. This segmentation interrupts the formation of large eddy current loops, reducing eddy current interference and improving sensing accuracy while maintaining the compact internal structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Insulating patterns are introduced as intermediary elements between the metal conductive parts, preventing direct electrical contact and blocking eddy current paths. These insulating patterns act as mediators that reduce eddy current interference without compromising the electrical functionality of the power module.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If the metal conductive part is divided into segments, then eddy currents are reduced, but device complexity increases

Engineering Contradiction:

Improvesensing accuracyVSAvoidconductive part structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

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

The solution allows for precise current sensing within a compact power module design, reducing volume and cost while enhancing the Hall element's accuracy by minimizing eddy current interference.

Implementation Method 1

a sensor part installed on the metal conductive part of the substrate and configured to sense the current flowing in the semiconductor chip or the metal conductive part

Methodology Applied

Scientific EffectHall effect: Hall Effect

Implementation Method 2

an eddy current reduction pattern part configured to reduce an eddy current around the sensor part by dividing the metal conductive part around the sensor part into a plurality of segments

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Data Source

PatentUS20260029437A1Power Module

Publication Date: 2026.01.29 HYUNDAI MOTOR CO LTD

AI summary

A power module is configured to provide sensing current through a Hall element. By sensing current through a Hall element, reducing the volume and cost for current sensing can be provided. In addition, by reducing the influence of eddy currents on the Hall element, the sensing accuracy of the Hall element may be improved.