An Integrated Power Module Based on the Power-System-In-Inductor Structure

This paper presents an integrated power module with the features of high power density and high efficiency. A multifunctional integrated magnetic component is designed. The component has the roles of both the filter inductor and the package of the converter. With the assist of finite-element analysis, the design and optimization of the proposed inductor are demonstrated. It has higher inductance value than the inductor used in conventional designs. The package is composed of bigger copper winding and higher thermal conductive magnetic material, leading to lower direct current resistance and better thermal performances than conventional transfer molding packaging. Benefiting from these advantages, the power module built based on the inductor can achieve higher efficiency and lower temperature rise than those based on traditional plastic packaging solution. 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 module is analyzed. The performances of the proposed power module are better than the conventional transfer molding packaging solution with the same board or other state-of-art products.