Power Module Resin Housing for Integrated Magnetic Sensor Positioning
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Solution Overview
Problem
Existing power modules face challenges in simplifying and downsizing their configuration while effectively shielding components and integrating magnetic detection units.
Innovation Solution
The power module design incorporates an outer wall resin with insertion holes that match the shape of magnetic detection units, allowing for precise fitting and fixation, and uses adhesive to secure the units in place, ensuring the magnetic detection units are positioned correctly and protected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If magnetic detection units are integrated into the power module, then sensing capability is improved, but device complexity increases
Solution Approach 1:
The magnetic detection unit is integrated directly into the power module structure, merging the sensing function with the power module components. The detection unit includes a detection element mounted on a circuit board that is embedded within the power module, allowing sensing capability to be incorporated without adding separate external sensing components.
Solution Approach 2:
The circuit board serves multiple functions: it provides electrical connections for power transmission and simultaneously supports the magnetic detection element for sensing operations. This multi-functional design allows the same structural component to handle both power delivery and sensing tasks, reducing overall device complexity.
2Object-affected harmful factors
If outer wall resin covers the magnetic detection unit, then shielding effectiveness is improved, but detection precision may deteriorate
Solution Approach 1:
The outer wall resin is designed with a localized detection portion that corresponds to the position of the magnetic detection element. This detection portion has different properties from the rest of the resin body - specifically, it allows magnetic field penetration while the main body provides shielding. This local differentiation enables both shielding and detection functions to coexist without compromising detection precision.
Data Source
AI summary
A power module has a bus bar, a magnetic detection unit, and outer wall resin, in which the outer wall resin has an insertion hole into which the magnetic detection unit is inserted, and when seen from an insertion direction of the magnetic detection unit, the insertion hole has a shape corresponding to an outer shape of the magnetic detection unit. There is provided a method of manufacturing a power module which has a bus bar and a magnetic detection unit, the method of manufacturing a power module including: performing resin molding on the bus bar, and forming outer wall resin having an insertion hole into which the magnetic detection unit is inserted; and inserting the magnetic detection unit into the insertion hole.