Power Module Packaging with Removable End-Cap Connection Terminals

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Solution Overview

Problem

Current protection processes for electrical connection structures in power module packaging increase the complexity of the packaging process and may compromise the integrity of these connections.

Innovation Solution

A method involving the use of electrical connection terminals with an extension portion and end cap, where the end cap is removed post-packaging to expose a hollow cavity, allowing for simple and effective external electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a protection process is applied to electrical connection structures after packaging, then the integrity of electrical connections is ensured, but the packaging process complexity increases

Engineering Contradiction:

Improveintegrity of electrical connectionsVSAvoidpackaging process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The end cap is installed on the electrical connection terminal before the packaging process, providing preliminary protection to the hollow cavity and electrical connection structures. This preliminary protective measure eliminates the need for complex post-packaging protection processes, as the end cap remains in place throughout packaging and only needs to be removed after the module is fully assembled and protected by the encapsulant.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The end cap serves as an intermediary protective element between the hollow cavity/electrical connection structures and the external environment during packaging. It temporarily protects the internal structures without requiring complex protection processes, and is easily removed after packaging when no longer needed.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If electrical connection structures are exposed after packaging, then external electrical connection is enabled, but the risk of damage during packaging increases

Engineering Contradiction:

Improveexternal electrical connectionVSAvoidintegrity of electrical connections

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The end cap is pre-installed on the electrical connection terminal before packaging to protect the hollow cavity and electrical connection structures. This preliminary protective measure ensures that the electrical connections remain intact throughout the packaging process, and only after packaging is complete is the end cap removed to enable external electrical connection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The end cap provides beforehand protection (cushioning) to the electrical connection structures and hollow cavity during the packaging process. This protective barrier prevents damage to the electrical connections while maintaining the simplicity of the packaging process, and is removed after packaging when the encapsulant provides overall protection.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If the end cap is kept on the electrical connection terminal, then the hollow cavity is protected, but the external electrical connection becomes difficult

Engineering Contradiction:

Improveprotection of hollow cavityVSAvoidexternal electrical connection

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The end cap is installed in advance to protect the hollow cavity during packaging, and is designed to be easily removed after packaging when no longer needed. This preliminary protective measure enables the hollow cavity to remain protected throughout the critical packaging phase while allowing simple removal for external connection afterward.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The end cap serves as a temporary protective element that is discarded (removed) after it has fulfilled its protective function during packaging. Once the packaging is complete and the encapsulant provides ongoing protection, the end cap is removed to enable external electrical connection, having served its purpose and been recovered from the system.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS12389553B2Method for forming power module package, power module package and electronic device

Publication Date: 2025.08.12 DELTA ELECTRONICS INC(CN)

AI summary

A method for forming a power module package includes providing a power module including an electrical element and an electrical connection portion; providing an electrical connection terminal including a connection end, an extension portion and an end cap, wherein the extension portion is extended between the connection end and the end cap and has a hollow cavity therein; disposing the electrical connection terminal on the electrical connection portion for electrically connecting the connection end to a corresponding electrical connection portion; packaging the power module and the electrical connection terminal through an encapsulant to form a packaged body; removing a portion of a surface of the packaged body for exposing the end cap of the electrical connection terminal; and removing the end cap to expose the hollow cavity of the electrical connection terminal, so as to form the power module package.