Power Supply Module With Metal Core Substrate For Wireless Sensors
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Solution Overview
Problem
Existing wireless sensor modules are restricted in size and thickness due to the battery holder, making it difficult to create a small and thin form factor, and the battery's limited capacity leads to short operating times due to high power consumption by the transmission circuit.
Innovation Solution
A power supply module is designed using a metal core substrate with insulation layers, where the battery is directly mounted on the substrate, eliminating the need for a holder and allowing for efficient heat dissipation, and a circuit board with a voltage conversion circuit is stacked on top, using through-electrodes to connect the battery terminals to the circuit board, enabling a compact and thin design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a battery holder is used to accommodate the battery, then the battery can be securely mounted, but the size and thickness of the wireless sensor module increase
Solution Approach 1:
The battery holder function is merged with the circuit board by forming a recess portion directly on the circuit board substrate. This integration eliminates the need for a separate holder component, reducing overall module size and thickness while maintaining secure battery mounting through the recess structure that physically constrains the battery in place
Solution Approach 2:
The circuit board is designed to serve multiple functions: it provides electrical connections through pads and conductors, and simultaneously acts as the battery holder through the recess portion. This multi-functionality reduces the total component count and enables a more compact module design without compromising battery security
2Volume of moving object
If a small capacity battery is used to reduce module size, then the module becomes more compact, but the operating time decreases due to high power consumption
Solution Approach 1:
The voltage conversion circuit dynamically adjusts output voltage parameters based on the power consumption requirements of different components. By optimizing voltage levels for the sensor, microcomputer, and transmission circuit, the system minimizes power consumption, enabling the use of smaller capacity batteries while maintaining adequate operating time
3Temperature
If the battery is directly mounted on the metal core substrate, then heat dissipation is improved, but electrical insulation must be carefully managed
Solution Approach 1:
An insulation layer is introduced as an intermediary between the metal core substrate and the battery. This insulation layer serves dual purposes: it provides electrical isolation to prevent short circuits between the battery terminals and the conductive substrate, while still allowing thermal energy to pass through for effective heat dissipation from the battery
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 allows for a small and thin power supply module that is not restricted by the battery's thickness, effectively radiating heat and supplying power to the wireless sensor module, thereby extending its operating time and enabling a compact wireless sensor module.
Implementation Method 1
the battery is directly mounted on the substrate, eliminating the need for a holder and allowing for effective heat dissipation
Implementation Method 2
a circuit board having a voltage conversion circuit configured to convert a voltage of the battery into a predetermined voltage
Data Source
AI summary
A package includes a metal core substrate, a first insulation layer formed along a periphery of a first surface of the metal core substrate, the first surface of the metal core substrate being exposed at an inner side of the first insulation layer, a second insulation layer formed along at least a periphery of a second surface of the metal core substrate, a first through-electrode penetrating the second insulation layer at a first part of the periphery of the metal core substrate, and a second through-electrode penetrating the first insulation layer, the metal core substrate and the second insulation layer at a second part of the periphery of the metal core substrate, the second through-electrode being electrically insulated from the metal core substrate via an insulation member.