Vertically Stacked Power and Control Packages for Compact Integration
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Solution Overview
Problem
Conventional power modules face challenges in providing customized solutions due to varying control circuits, high fabrication costs, and limited integration capabilities, making them uneconomic and difficult to miniaturize.
Innovation Solution
A power module design where a power package and a control package are fabricated separately and vertically stacked, allowing for electrical coupling and independent optimization, reducing costs and enabling high integration and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the power device and control device are disposed on the same horizontal plane in one package, then the package can be formed as a single unit, but it is difficult to reduce the size of the package and achieve high integration
Solution Approach 1:
The patent transitions from a two-dimensional horizontal arrangement to a three-dimensional vertical stacking configuration. The power device and control device are disposed on different horizontal planes and stacked vertically, utilizing the vertical dimension to reduce the overall package footprint while maintaining all necessary functional components within a compact volume.
2Adaptability or versatility
If various control circuits are customized according to different product types, then customer demands can be met, but it is difficult to provide different power modules due to productivity constraints
Solution Approach 1:
The power module is divided into independent functional segments: a power device portion and a control device portion. Each segment can be designed, manufactured, and tested separately, then assembled into different module configurations to meet diverse customer requirements. This modular segmentation enables customization without compromising production efficiency.
3Reliability
If the control device is added to the power device to form a package, then the power module can be enhanced with control functionality, but the fabrication costs increase significantly
Solution Approach 1:
The patent merges the power device and control device into a single integrated power module package. By combining these previously separate components into one unified module with shared packaging and interconnection structures, the design achieves cost-effective integration while maintaining reliable control functionality alongside power processing capabilities.
Data Source
AI summary
Provided are a power module including a power package and a control package that are provided separately and can be highly integrated, and method of fabricating the power module. The power module includes: a molded power package including at least one power device on a first lead frame; and a molded control package vertically stacked on the power package, and including at least one control device on a second lead frame. A first part of the first lead frame and a first part of the second lead frame are coupled to each other so that the power package and the control package can be electrically coupled to each other.