Power Module
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Solution Overview
Problem
Existing power modules face challenges in accurately sensing current due to the influence of eddy currents, which increases volume and cost when current sensors are provided outside the module, and reduces accuracy when inside.
Innovation Solution
A power module with a Hall element that senses current internally, utilizing an eddy current reduction pattern to divide the metal conductive part into segments, reducing eddy currents and improving sensing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a current sensor is provided outside the power module, then current sensing is enabled, but the overall volume increases
Solution Approach 1:
The current sensor (Hall element) is integrated directly into the power module substrate, merging the sensing function with the power module structure. This eliminates the need for separate external current sensors, thereby reducing overall volume while maintaining current sensing capability.
2Volume of stationary object
If a current sensor is provided inside the power module, then volume is reduced, but sensing accuracy deteriorates due to surrounding interference factors
Solution Approach 1:
The Hall element is positioned at a specific location on the substrate where it can sense current through the metal conductive part while being electrically isolated from high-current paths. The eddy current reduction pattern part extracts or mitigates the harmful eddy currents that would otherwise interfere with sensing accuracy.
Solution Approach 2:
The metal conductive part serves as an intermediary element that carries the main current while allowing the Hall element to sense the magnetic field generated by this current. The eddy current reduction pattern acts as a mediator to minimize electromagnetic interference between the high-current metal conductive part and the sensitive Hall element.
3Reliability
If the metal conductive part is kept as a single continuous structure, then electrical conductivity is maintained, but eddy currents increase around the sensor part
Solution Approach 1:
The metal conductive part is divided into multiple segments by the eddy current reduction pattern part. This segmentation interrupts the continuous metal path, preventing large eddy currents from forming around the sensor area while still maintaining necessary electrical conductivity for power transmission through the segmented structure.
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 reduced volume and cost, mitigating the impact of eddy currents on the Hall element, enhancing sensing accuracy.
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
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
Data Source
AI summary
A power module is proposed 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.