Power Module Current Sensing With Segmented Magnetic Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power modules face challenges in easily integrating a current sensor, which complicates manufacturing and requires additional space, leading to increased resistance and calibration needs.
Innovation Solution
A power module design that incorporates a first core part surrounding the conductor, forming a magnetic core with a second core part to enhance sensitivity for Hall sensors, allowing for easy fabrication and space-efficient integration of the current sensor, with the core parts being fixed using mold material or gel for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a complete magnetic core is integrated into the power module for current sensing, then measurement precision is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The magnetic core is divided into two separate parts: a first core part integrated into the power module base and a second core part that can be added later. This segmentation allows the current sensor to be manufactured easily in the power module while completing the magnetic core structure in a subsequent step, thereby reducing initial device complexity while maintaining measurement precision.
2Measurement precision
If a complete magnetic core is integrated into the power module, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
By segmenting the magnetic core into two parts manufactured at different stages, the power module can be produced using standard processes without requiring complex integrated core structures. The second core part is added in a simpler subsequent step, improving overall ease of manufacture while achieving the same measurement precision as a complete integrated core.
3Adaptability or versatility
If Hall sensors are used for current sensing, then measurement capability is improved, but sensitivity is insufficient without a magnetic core
Solution Approach 1:
The segmented magnetic core design allows Hall sensors to be integrated in the power module with the first core part, providing current sensing capability. The second core part is added later to complete the magnetic circuit, thereby achieving high sensitivity. This approach enables progressive implementation: initial sensing capability with the first core part, and enhanced sensitivity after adding the second core part.
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
Facilitates easy and space-saving integration of an integrated current sensor, improving sensitivity and reducing the need for calibration, while maintaining mechanical and electrical security through secure fixation methods.
Implementation Method 1
The core can especially be used to increase the sensitivity compared with using a Hall sensor alone. The core may direct a magnetic field to a Hall sensor, so that the Hall sensor can detect the magnetic field.
Implementation Method 2
The core may direct a magnetic field to a Hall sensor, so that the Hall sensor can detect the magnetic field.
Data Source
AI summary
The disclosure relates to a power module including a semiconductor power circuit, a conductor and a first core part being arranged besides the conductor such that it can form a core together with a second core part. The disclosure further relates to methods for manufacturing such a power module.