Power Module Ground Segmentation for Noise Isolation
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Solution Overview
Problem
High-speed switching in power modules can cause noise to be transferred from the power circuit to the control circuit due to potential fluctuations in the power GND, leading to erroneous turn-on of power semiconductors and potential damage.
Innovation Solution
A power module configuration where the ground of the power circuit and control circuit are separated, with at least part of the control output circuit facing the control circuit ground in different layers via an insulating layer, and the use of insulated gate drivers to prevent noise transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high-speed switching is implemented in power modules, then switching speed is improved, but noise is transferred from power circuit to control circuit due to potential fluctuation of power GND
Solution Approach 1:
The patent divides the GND into separate domains: power GND for the power circuit and control GND for the control circuit. This segmentation prevents noise generated by high-speed switching in the power circuit from being transferred to the control circuit, while still allowing both circuits to operate at high speeds.
Solution Approach 2:
The patent introduces an insulating layer as an intermediary between the power GND and control GND. This insulating layer electrically isolates the two GND systems, blocking the noise transfer path while maintaining the high-speed switching capability of both circuits.
2Device complexity
If control output circuit is arranged to face power GND in different layers, then integration is improved, but noise is transferred to control output circuit due to induced electromotive force from power GND potential fluctuation
Solution Approach 1:
The patent segments the GND system into power GND and control GND, allowing the control output circuit to be positioned in different layers facing the power GND for better integration, while the insulating layer prevents noise coupling through the GND structure.
Solution Approach 2:
The insulating layer acts as an intermediary that electrically isolates the control output circuit from the power GND potential fluctuations, preventing induced electromotive force while allowing close physical proximity for integrated design.
3Reliability
If source electrode of MOSFET and source electrode of driver circuit are connected via metal wiring, then electrical connection is improved, but potential fluctuation of power GND causes noise transfer to control circuit
Solution Approach 1:
The patent segments the GND connection path by introducing an insulating layer between power GND and control GND, while maintaining reliable electrical connections within each domain through metal wiring. This ensures low-impedance connections locally while blocking noise transfer globally.
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
This configuration effectively suppresses noise transfer from the power GND to the control output circuit during switching, reducing the risk of erroneous turn-on and improving switching efficiency.
Implementation Method 1
there is a possibility that noise is transferred to the control output circuit due to induced electromotive force. In other words, there is a possibility that noise of the power GND is transferred to the control output circuit that is arranged at a position to face the power GND in a different layer via an insulating material.
Data Source
AI summary
A power module includes a power circuit which includes one or more power semiconductors; and a control circuit which supplies a gate signal to each of the one or more power semiconductors. The control circuit includes one or more gate drivers which generate the gate signal in accordance with a control signal and in which a side to which the control signal is input and a side on which the gate signal is generated are insulated, a control input circuit to which the control signal is input and which supplies the control signal to the one or more gate drivers, and a control output circuit which supplies the gate signal to each of the power semiconductors.