Power System Module Segmentation for Integration and Flexibility
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Solution Overview
Problem
Conventional power system modules are inflexible, costly, and difficult to integrate due to the need for custom control circuitry and the inclusion of both power and control devices in a single package, which increases manufacturing complexity and reduces integration capabilities.
Innovation Solution
A power system module design featuring a plastic case with separate regions for a molding-type power module package and a control circuit board, allowing for easy customization and integration by electrically connecting external terminals and leads using solder, enabling separate manufacturing of power and control components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a power device and control device are stacked and molded on a single lead frame, then integration is achieved, but manufacturing flexibility and adaptability to customer requirements deteriorate
Solution Approach 1:
The invention divides the power system module into two separate packages: a power module package containing the power device and a control module package containing the control device. This segmentation allows each package to be manufactured independently according to different customer requirements, improving manufacturing flexibility while maintaining the integrated functionality of the complete system.
Solution Approach 2:
The control module package is positioned to surround or nest around the power module package, with the control device electrically connected to the power device through leads that pass through the control module package. This nesting arrangement achieves spatial integration and electrical connectivity while preserving the modular structure that enables manufacturing flexibility.
2Reliability
If a control device is added to an already expensive power module package, then control functionality is improved, but cost increases
Solution Approach 1:
By separating the control device into its own package, the invention enables independent manufacturing and sourcing of the control module. This allows customers to choose different control device configurations based on their specific needs, optimizing cost-effectiveness while ensuring reliable control functionality.
Solution Approach 2:
The control module package can be designed with universal mounting and connection interfaces that accommodate various control device types. This universality allows the same package structure to support different control functionalities, reducing development costs and enabling cost-effective customization for different applications.
3Device complexity
If a power device and control device are both contained in a single package, then integration is achieved, but the ability to provide customized solutions deteriorates
Solution Approach 1:
The invention segments the power and control functions into separate packages, allowing each to be independently customized. The power module package can be configured with different power devices and parameters, while the control module package can be customized with different control devices, enabling tailored solutions for specific customer requirements while maintaining integrated system functionality.
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 design allows for cost-effective, high integration of power system modules that can be tailored to customer specifications, reducing manufacturing costs and enhancing circuit integration by separating power and control components within a shared plastic case.
Implementation Method 1
the lead of the power module package and the second hole of the control circuit board may pass through and be electrically connected with conductive solder
Data Source
AI summary
Provided are a power system module allowing a user's requirements to be easily met, and having economic practicality and high integration, and a manufacturing method thereof. The power system module includes a plastic case, a molding type power module package, a control circuit board, and at least one external terminal. The plastic case defines a bottom and a side wall. The molding type power module package is fixed to the bottom of the plastic case and includes at least a power device therein. The control circuit board is fixed to the side wall of the plastic case, includes at least a control device mounted thereon which is electrically connected to the power module package. The external terminal protrudes to outside the plastic case and is electrically connected to the control circuit board.