An innovative power module with power-system-in-inductor structure

This paper presents an integrated power module with the features of high power density and high efficiency. A multi-functional integrated magnetic component is designed. The component has the roles of both the filter inductor and the case of the whole power module. With the assist of finite element analysis (FEA), design and optimization of the proposed inductor are demonstrated. It has higher inductance value than the inductor used in conventional designs. It has bigger coil winding and larger surface area, leading to lower DCR and better thermal performances than plastic packaging. Benefiting from these advantages, the power module constructed based on the inductor can achieve higher efficiency and lower temperature than those based on traditional plastic packaging solutions. Design of the inductor is demonstrated through the combination of analytical and simulation methods. An inductor prototype is built and used in an integrated power module to do experimental tests. Loss breakdown of the power module is executed to show the loss of the magnetic component. The proposed power module shows better performances than the plastic packaging solution.