Power module and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-11277067-B2
Application number	US-201816130850-A
Country	US
Kind code	B2
Filing date	Sep 13, 2018
Priority date	Mar 3, 2016
Publication date	Mar 15, 2022
Grant date	Mar 15, 2022

Abstract

A power module and a manufacturing method thereof are disclosed. The power module includes a magnetic component, a bare power chip and a conductive set. The magnetic component includes a first surface and a second surface opposite to each other. The bare power chip is disposed on the magnetic component and includes a third surface and a fourth surface opposite to each other. The conductive set is disposed on the magnetic component and electrically connected with the magnetic component and the bare power chip. The third or fourth surface of the bare power chip is at least partially attached on the first or second surface of the magnetic component, and at least partially included in a projected envelopment of the corresponding first or second surface of the magnetic component, so as to facilitate the magnetic component to support the bare power chip.

First claim

What is claimed is:

1. A power module comprising:
at least one magnetic component comprising a main body, at least one winding set, a first surface and a second surface, wherein the at least one winding set is embedded in the main body and comprises two vertical portions, wherein the two vertical portions are led out to form two leading pins on one of the first surface and the second surface of the at least one magnetic component, respectively, and the first surface is opposite to the second surface;
at least one bare power chip disposed on the at least one magnetic component and comprising a third surface and a fourth surface, wherein the third surface is opposite to the fourth surface; and
at least one conductive set stacked on one of the first surface and the second surface of the at least one magnetic component and electrically connected with the at least one magnetic component and the at least one bare power chip;
wherein one of the third surface and the fourth surface of the at least one bare power chip is at least partially attached on one of the first surface and the second surface of the at least one magnetic component, and one of the third surface and the fourth surface of the at least one bare power chip is at least partially included in a projected envelopment of the corresponding one of the first surface and the second surface of the at least one magnetic component, so as to facilitate the at least one magnetic component to support the at least one bare power chip.

2. The power module according to claim 1 , further comprising a first insulation layer disposed around at least one lateral wall, and on one of the first surface and the second surface of the at least one magnetic component, wherein one of the third surface and the fourth surface of the at least one bare power chip is included in a projected envelopment of the at least one magnetic component and the first insulation layer, so as to facilitate the at least one magnetic component and the first insulation layer to support the at least one bare power chip.

3. The power module according to claim 2 , wherein the at least one magnetic component comprises at least two magnetic components, and the first surfaces of the at least two magnetic components or the second surfaces of the at least two magnetic components are coplanar.

4. The power module according to claim 2 , further comprising at least one component mounted in the first insulation layer, wherein at least one surface of the at least one component and the first surface of the magnetic component are coplanar or the at least one surface of the at least one component and the second surface of the magnetic component are coplanar.

5. The power module according to claim 1 , further comprising an adhesion layer disposed between the at least one bare power chip and the at least one magnetic component, to make one of the third surface and the fourth surface of the at least one bare power chip at least partially attached on the corresponding one of the first surface and the second surface of the at least one magnetic component.

6. The power module according to claim 1 , further comprising a second insulation layer disposed on one of the first surface and the second surface of the at least one magnetic component and covering the corresponding at least one bare power chip.

7. The power module according to claim 6 , wherein the at least one conductive set comprises at least one conductive via and at least one first metallization layer, the at least one first metallization layer is disposed on the second insulation layer, and the at least one first metallization layer is connected to one of the third surface of the at least one bare power chip, the fourth surface of the at least one bare power chip, the first surface of the at least one magnetic component and the second surface of the at least one magnetic component through the at least one conductive via.

8. The power module according to claim 7 , further comprising a third insulation layer disposed on the second insulation layer, wherein the conductive set comprises at least one second metallization layer disposed on the third insulation layer and the at least one first metallization layer and the at least one second metallization layer are electrically connected with each other, wherein the at least one bare power chip and the at least one magnetic component are electrically connected with each other through the at least one first metallization layer.

9. The power module according to claim 7 , wherein the at least one bare power chip comprises at least one electrode disposed on one of the third surface and the fourth surface of the at least one bare power chip and electrically connected with the at least one magnetic component through the at least one conductive set.

10. The power module according to claim 7 , wherein the at least one magnetic component comprises at least one terminal disposed on one of the first surface and the second surface of the magnetic component and electrically connected with the at least one bare power chip through the at least one conductive set.

11. The power module according to claim 4 , wherein the at least one magnetic component comprises at least one recess disposed on one of the first surface and the second surface thereof, wherein one of the third surface and the fourth surface of the at least one bare power chip is at least partially attached on the corresponding one of the first surface and the second surface of the at least one magnetic component, and one of the at least one bare power chip and the at least component is at least partially received within the at least one recess.

12. The power module according to claim 1 , further comprising at least one component and at least one solder ball, wherein the at least one component is disposed on the at least one magnetic component and electrically connected with the at least one bare power chip and the at least one magnetic component through the at least one conductive set, wherein the at least one solder ball is disposed on the at least one conductive set, located nearby a side of the at least one component, and has a height larger than or equal to a height of the at least one component.

13. The power module according to claim 1 , wherein the at least one conductive set comprises at least one solder ball or at least one wire bond electrically connected with one of the at least one bare power chip and the at least one magnetic component.

14. The power module according to claim 1 , wherein the at least one conductive set comprises at least one wire bond electrically connected between the at least one bare power chip and the at least one magnetic component.

15. The power module according to claim 2 , wherein the at least one conductive set comprises at least one first metallization layer, at least second metallization layer and at least one conductive block, wherein the at least one first metallization layer and the at least one second metallization layer are disposed on the first surface and the second surface of the magnetic component, respectively, and the conductive block is disposed within the at least one first insulation layer and is electrically connected between the at least one first metallization layer and the at least one second metallization layers.

16. The power module according to claim 15 , wherein the at least one bare power chip and the at least one winding set are electrically connected with each other through the at least one first metallization layer, and the at least one first metallization layer electrically connected with the at least one second meta

Assignees

• Delta Electronics Inc

Inventors

• Hong Shouyu
• Chen Qingdong
• Lu Kai
• Ji Pengkai
• Xin Xiaoni
• Zhou Min
• Zhang Yu
• Zeng Jianhong

Classifications

• H10W90/00

  Package configurations · CPC title

• H02M3/1555

  for the generation of a regulated current to a load whose impedance is substantially inductive · CPC title

• H01F41/122

  Insulating between turns or between winding layers · CPC title

• H02M3/1582 Primary

  Buck-boost converters (H02M3/1584 takes precedence) · CPC title

• H02M3/1588

  comprising at least one synchronous rectifier element (H02M3/1582, H02M3/1584 take precedence) · CPC title