Switching Module Control Loop Layout for Lower Inductance EMI
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Solution Overview
Problem
High-frequency operation in switching modules leads to increased switching loss and electromagnetic interference due to mutual inductance between power and control loops, causing reliability issues and oscillations, which conventional technologies fail to adequately address.
Innovation Solution
The switching module design includes a substrate with switching elements and control/power parts arranged such that the projection areas of the control parts intersect, dividing the control loop into sub-loops with equal magnetic fluxes, thereby reducing mutual and self-inductance, and using additional magnetic flux compensation to minimize total mutual inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the switching module is operated at high frequency to achieve high power density, then the power density is improved, but the switching loss increases and electromagnetic interference worsens
Solution Approach 1:
The control loop is segmented into multiple sub-loops by arranging control traces to form intersecting projection areas. This segmentation reduces the self-inductance of the control loop, allowing faster switching speeds that reduce switching loss while maintaining high frequency operation for high power density.
Solution Approach 2:
The patent uses the spatial dimension by arranging control parts in three-dimensional space such that their projection areas intersect on a reference plane. This dimensional arrangement reduces mutual inductance between power and control loops, enabling high-frequency operation with reduced electromagnetic interference and switching loss.
2Loss of energy
If the switching speed is increased to reduce switching loss, then the switching loss is reduced, but electromagnetic interference worsens
Solution Approach 1:
By segmenting the control loop into sub-loops with intersecting projection areas, the patent reduces self-inductance, enabling faster switching speeds that reduce switching loss while the segmented structure simultaneously reduces electromagnetic interference through reduced loop area.
Solution Approach 2:
The patent converts the harmful effect of high-frequency switching (increased electromagnetic interference) into a benefit by using the high frequency to reduce switching loss, while the intersecting projection area design neutralizes the electromagnetic interference issue by reducing mutual and self-inductance.
3Power
If the distance between power loop and control loop is reduced to achieve high power density, then the power density is improved, but mutual inductance increases causing electromagnetic interference
Solution Approach 1:
The patent resolves the contradiction by moving to the projection dimension - arranging control parts in space such that their projection areas intersect on a reference plane. This dimensional approach reduces mutual inductance even when physical distances are reduced, enabling high power density without increased electromagnetic interference.
Solution Approach 2:
The patent uses asymmetric arrangement of control parts relative to power loops, positioning them such that their projection areas intersect in specific patterns. This asymmetric configuration optimizes the reduction of mutual inductance while maintaining compact high-density structure.
4Device complexity
If the self-inductance of control loop is large, then the structure is simpler, but oscillation occurs during switching process reducing safety performance
Solution Approach 1:
The patent segments the control loop into multiple sub-loops with intersecting projection areas. This segmentation inherently reduces self-inductance, preventing oscillation during switching while maintaining a relatively simple overall structure that integrates seamlessly into the power module.
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 effectively reduces mutual and self-inductance, enhancing the safety performance and reliability of the switching module by minimizing electromagnetic interference and oscillations.
Implementation Method 1
When the current in the power loop changes, an induced magnetic field is generated around the power loop. When the induced magnetic field passes through the control loop, a corresponding induced voltage is generated.
Implementation Method 2
dividing the control loop into sub-loops with equal magnetic fluxes, thereby reducing mutual and self-inductance
Data Source
AI summary
A switching module includes a substrate, a switching element, a first control part, a second control part, a first power part and a second power part. The switching element is disposed on the substrate. The switching element includes a first control terminal, a second control terminal, a first power terminal and a second power terminal. The first control part is connected with the first control terminal of the switching element. The second control part is connected with the second control terminal of the switching element. A projection area of the first control part on a reference plane intersects with a projection area of the second control part on the reference plane at one or more first intersections. The first power part is connected with the first power terminal of the switching element. The second power part is connected with the second power terminal of the switching element.