阅读说明：本技术 电源模块及电源模块的制备方法 (Power module and preparation method thereof ) 是由 季鹏凯 洪守玉 叶益青 于 2019-08-30 设计创作，主要内容包括：本发明提供一种电源模块及电源模块的制备方法,该电源模块包括芯片、被动元件和连接引脚,连接引脚设置于电源模块的出引脚面,连接引脚电连接芯片的芯片端子和被动元件中的至少其中之一；芯片在电源模块的出引脚面上的投影与被动元件在电源模块的出引脚面上的投影没有重叠,且芯片的出端子面与电源模块的出引脚面之间的夹角大于45°,小于135°。通过采用本发明的电源模块及电源模块的制备方法,由于芯片与被动元件平铺设置,相比堆叠式结构更易实现更小高度的电源模块；由于芯片基本上竖直放置,芯片与被动元件的连接更加直接,可减小电流阻抗和损耗或寄生电感,也利于减小电源模块的占地面积,使得结构更紧凑,功率密度更高。(The invention provides a power module and a preparation method thereof, wherein the power module comprises a chip, a passive element and a connecting pin, the connecting pin is arranged on a pin-out surface of the power module, and the connecting pin is electrically connected with at least one of a chip terminal of the chip and the passive element; the projection of the chip on the pin outlet surface of the power module is not overlapped with the projection of the passive element on the pin outlet surface of the power module, and the included angle between the pin outlet surface of the chip and the pin outlet surface of the power module is larger than 45 degrees and smaller than 135 degrees. By adopting the power module and the preparation method of the power module, the chip and the passive element are arranged in a tiled manner, so that the power module with smaller height is easier to realize compared with a stacked structure; because the chip is basically vertically arranged, the chip is more directly connected with the passive element, the current impedance and the loss or the parasitic inductance can be reduced, the occupied area of the power module is favorably reduced, the structure is more compact, and the power density is higher.)

1. A power module, comprising:

the chip comprises a chip, wherein a chip terminal is arranged on the outgoing terminal surface of the chip;

a passive element electrically connected to a chip terminal of the chip; and

the connecting pins are arranged on the pin outlet surfaces of the power supply modules and are electrically connected with at least one of the chip terminals of the chip and the passive elements;

the projection of the chip on the pin outlet surface of the power module is not overlapped with the projection of the passive element on the pin outlet surface of the power module, and the included angle between the pin outlet surface of the chip and the pin outlet surface of the power module is larger than 45 degrees and smaller than 135 degrees.

2. The power module of claim 1, wherein the output terminal face of the chip is perpendicular to the output pin face of the power module.

3. The power module of claim 1, wherein the power module comprises two opposing lead-out faces, the two opposing lead-out faces having the connection pins disposed thereon, respectively;

the power module comprises a plurality of chips, and the projections of the chips on the pin-out surfaces of the power module are not overlapped.

4. The power supply module of claim 1, wherein an interior of the power supply module is filled with an encapsulation material;

the power supply module further comprises a connecting layer, the connecting layer is located between the pin-out surface of the power supply module and the chip, and the connecting pins are electrically connected with at least one of the chip terminals of the chip and the passive element through the connecting layer.

5. The power module as claimed in claim 1, wherein the power module comprises two chip sets, each chip set comprises at least one chip, and the output terminal faces of the two chip sets are arranged face to face;

at least one passive element is arranged between the outgoing terminal surfaces of the two chip sets.

6. The power module of claim 1, wherein the power module comprises a first chipset and a second chipset, each of the first chipset and the second chipset comprising at least one of the chips;

the passive element comprises a magnetic element, the magnetic element comprises a first winding and a second winding, the first winding is electrically connected with the first chip set, and the second winding is electrically connected with the second chip set;

the magnetic element includes at least one of a coupled inductor, a non-coupled inductor, a planar transformer, and a foil-wound transformer.

7. The power module of claim 6, wherein the chips in the first chip set are disposed on a first side and a second side of the magnetic element, respectively, and the chips in the second chip set are disposed on a first side and a second side of the magnetic element, respectively, the first side being opposite to the second side.

8. The power module of claim 6, wherein the first chip set comprises two first chips connected in series, and the second chip set comprises two second chips connected in series, and a connection point of the two first chips connected in series is electrically connected to the first winding, and a connection point of the two second chips connected in series is electrically connected to the second winding.

9. The power module of claim 1, wherein the passive component comprises a multi-phase decoupling inductor, the multi-phase decoupling inductor comprises a plurality of windings arranged side by side, the power module comprises a chip in one-to-one correspondence with the windings, and the chip is electrically connected with the corresponding windings;

the chips electrically connected with the adjacent windings are arranged on the opposite sides of the multiphase decoupling inductor;

the center posts corresponding to the windings are arranged perpendicular to the pin outlet surfaces of the power supply modules, and the windings are wound back to the side surfaces of the chips and then electrically connected with the connecting pins.

10. The power module of claim 1, wherein the passive component comprises a multi-phase decoupling inductor, the multi-phase decoupling inductor comprises a plurality of windings arranged side by side, the power module comprises a chip in one-to-one correspondence with the windings, and the chip is electrically connected with the corresponding windings;

the chips are all arranged on the same side of the multiphase decoupling inductor;

the center post corresponding to each winding is arranged in parallel to the pin outlet surface of the power module, and the winding is bent and then electrically connected with the connecting pins on the opposite surface of the corresponding chip.

11. The power module of claim 1, wherein the passive component comprises a magnetic component, and a window of a core of the magnetic component is perpendicular to the pin-out surface of the power module, or a window of a core of the magnetic component is perpendicular to the terminal-out surface of the chip.

12. The power module of claim 1, wherein the passive component comprises at least one capacitor, and a length of the capacitor is perpendicular to a pin-out face of the power module.

13. The power module of claim 1, wherein the chip includes a back surface opposite the terminal-exiting surface, and conductive traces are connected between the back surface of the chip and a surface of the power module;

the conductive circuit is in contact with or electrically connected with the back surface of the chip through a conductive through hole, and the conductive circuit is exposed out of the surface of the power supply module; or

The conductive circuit is in contact with or electrically connected with the back surface of the chip, and the conductive circuit is connected with the surface of the power supply module through the conductive through hole.

14. The power module of claim 1, wherein a surface of the power module is provided with a thermally conductive post or plate.

15. The power supply module of claim 1, wherein each of the chips comprises one switching element, a plurality of switching elements connected in parallel, or two switching elements connected in series;

the chip and the passive element form at least one of a buck circuit, a boost circuit, a buck/boost circuit, an LLC circuit, a switched capacitor circuit, a Cuk circuit and a flyback circuit.

16. The preparation method of the power module is characterized by comprising the following steps of:

s100: stacking and packaging a passive element and a chip in a first packaging material, so that an included angle formed by the outgoing terminal surface of the chip and the stacking direction of the first packaging material is more than 45 degrees and less than 135 degrees, and the passive element is electrically connected with a chip terminal of the chip to form a power module connecting piece;

s200: cutting the power module connecting sheet along a first cutting surface to form a plurality of power modules, forming connecting pins by exposed conductive parts after cutting, and forming a first connecting layer between a pin outlet surface of each power module and the chip, wherein the first connecting layer is used for electrically connecting the connecting pins with at least one of chip terminals of the chip and the passive element;

in the formed power module, the projection of the chip on the pin outlet surface of the packaging material layer is not overlapped with the projection of the passive element on the pin outlet surface of the packaging material layer, and the included angle between the pin outlet surface of the chip and the pin outlet surface of the packaging material layer is larger than 45 degrees and smaller than 135 degrees.

17. The method for manufacturing a power module according to claim 16, wherein the step S200, after forming the individual power modules, further comprises the steps of:

s300: packaging the plurality of power modules in a second packaging material, wherein pin outlet surfaces of the plurality of power modules are arranged in a coplanar manner, a second connecting layer is formed in a second packaging material layer, the second connecting layer is electrically connected with the first connecting layer, and an included angle between the first connecting layer and the second connecting layer is larger than 45 degrees and smaller than 135 degrees, so that a second power module connecting piece is formed;

s400: and cutting the second power module connecting piece along a second cutting surface to form a single power module.

18. The method of claim 17, wherein after the step S300 of forming the second connection layer, the step S further includes encapsulating a chip on one side of the second connection layer.

19. The method of claim 16, wherein in step S100, the passive component includes at least one capacitor, and when the capacitor is encapsulated in the encapsulation material, a length direction of the capacitor is perpendicular to the first cut surface, or a length direction of the capacitor is parallel to the first cut surface.

20. The method for manufacturing a power module according to claim 16, wherein the step S100 of forming the power module connecting piece includes forming a passive component package connecting piece by the passive component package, forming a chip package connecting piece by the chip, welding the passive component package connecting piece and the chip package connecting piece, and electrically connecting the passive component and the chip to form the power module connecting piece.

21. The method for manufacturing a power module according to claim 16, wherein in step S100, the forming of the power module connection piece includes forming a passive component package connection piece by the passive component package, and packaging the chip by using the passive component package connection piece as a substrate to form the power module connection piece;

or, the chip package forms a chip package connecting piece, and the chip package connecting piece is used as a substrate to package the passive element to form a power module connecting piece.

Technical Field

The invention relates to the technical field of power electronic equipment, in particular to a power module and a preparation method of the power module.

Background

With the increasing demand for power and current, various smart integrated circuit chips have more and more functions, larger and larger power consumption, and more devices on the motherboard, which require a power module with higher power density or a single module with greater output current capability. In order to improve the efficiency, the dynamic performance and the integration level, the height requirement of the intelligent integrated circuit chip of the cloud or the terminal on the power supply module is higher and higher, and the bidirectional heat dissipation capability of the module is expected to be good; in addition, space constraints in data centers and smart terminals such as mobile phones also require power modules to have smaller heights.

Fig. 1 shows a cross-sectional view of one unit of a data center, showing a heat sink 72, a load chip 73, a data center motherboard 74, and a module housing 75. When the power module 100 is shown to be placed above the data center motherboard 74, it is often desirable for the power module to have a small height h1, e.g., less than 4mm, in view of sharing the heat sink 72 with an intelligent integrated circuit chip, particularly a load chip 73 such as a GPU (Graphics Processing Unit). When the power module 100 is mounted on the lower surface of the data center motherboard 74, the height h2 needs to be less than 2.5mm to satisfy most applications. Fig. 2 is a schematic diagram of the arrangement of the internal space of the mobile phone-like smart terminal, in which a mobile phone shell 78, a power supply module 100, a display 76, a battery 77 and a mobile phone motherboard 79 are shown. Compared with a data center, the space requirement in a mobile phone type intelligent terminal is more severe, for example, a cross-sectional view of a mobile phone is shown in fig. 2, and the height h3 of the upper surface or the height h4 of the lower surface of a mobile phone main board 79 is often only 1.2 mm.

Fig. 3 and 4 show two stacked power modules in the prior art, that is, a chip 1 and a passive element 2 are stacked up and down to form a power module, where the passive element 2 refers to a passive device such as an inductor, a capacitor, or a transformer, and the chip 1 and the passive element 2 are stacked to form the power module. This structure, while advantageous for reducing footprint, is more difficult to reduce in height because the height at which two devices are stacked together is always higher than the height of a single device. In addition, it is difficult to realize that the upper and lower surfaces of a single device have symmetrical heat dissipation performance, for example, in fig. 3, downward thermal resistance of the chip 1 is easy to be small, shielding thermal resistance passing upward through the passive element 2 is large, and downward heat dissipation performance of the chip 1 is better than upward heat dissipation performance. Therefore, the heat dissipation performance of one side is inferior to that of the other side, the heat dissipation performance of the other side needs to be matched with a heat dissipation path of an application environment in application, otherwise, the output capacity of actual power and current is easily influenced by the limitation of the heat dissipation path in the application environment.

For intelligent integrated circuit chip provides the power, except adopting heap power module, can also adopt comparatively traditional discrete device (discrete) to assemble into power module on the mainboard, tiling such as power device, inductance (promptly power device and inductance do not have the overlap on the projection of mainboard) place on the mainboard, walk the line through the mainboard each other and carry out electrical connection to load such as for intelligent integrated circuit chip provides the electric energy. In this way, the chip is usually soldered to the system motherboard with the terminal side facing the system motherboard, and the side of the chip with terminals is usually the side with larger surface area. Although a lower height can be realized, the chip is generally thinner, and the height of the passive element is generally higher than that of the chip, so that the space above the chip is wasted, in addition, the occupied area of the chip is larger, so that the whole occupied area of the power module is larger, in addition, the terminal of the chip faces to a circuit board (system main board) and does not face to the passive element, and the current transmission distance from the chip to the passive element is also longer. Therefore, the mode of assembling the power module by adopting the discrete devices has the problems that the yield problem, the floor area constraint problem and the demand for development resources are increased after the power demand is continuously improved due to numerous devices on the mainboard.

Disclosure of Invention

The invention aims to provide a power module and a preparation method thereof, wherein the height and the occupied area of the power module are smaller.

Additional features and advantages of the invention will be set forth in the detailed description which follows, or may be learned by practice of the invention.

According to a first aspect of the present invention, there is provided a power supply module comprising:

the chip comprises a chip, wherein a chip terminal is arranged on the outgoing terminal surface of the chip;

a passive element electrically connected to a chip terminal of the chip; and

the connecting pins are arranged on the pin outlet surfaces of the power supply modules and are electrically connected with at least one of the chip terminals of the chip and the passive elements;

the projection of the chip on the pin outlet surface of the power module is not overlapped with the projection of the passive element on the pin outlet surface of the power module, and the included angle between the pin outlet surface of the chip and the pin outlet surface of the power module is larger than 45 degrees and smaller than 135 degrees.

Optionally, the outgoing terminal surface of the chip is perpendicular to the outgoing pin surface of the power module.

Optionally, the power module includes two opposite outlet terminal surfaces, and the two opposite outlet terminal surfaces are respectively provided with the connection pins;

the power module comprises a plurality of chips, and the projections of the chips on the pin-out surfaces of the power module are not overlapped.

Optionally, the inside of the power module is filled with an encapsulation material;

the power supply module further comprises a connecting layer, the connecting layer is located between the pin-out surface of the power supply module and the chip, and the connecting pins are electrically connected with at least one of the chip terminals of the chip and the passive element through the connecting layer.

Optionally, the power module includes two chip sets, each chip set includes at least one chip, and the output terminal surfaces of the two chip sets are arranged face to face;

at least one passive element is arranged between the outgoing terminal surfaces of the two chip sets.

Optionally, the power module includes a first chipset and a second chipset, and the first chipset and the second chipset respectively include at least one chip; the passive element comprises a magnetic element, the magnetic element comprises a first winding and a second winding, the first winding is electrically connected with the first chip set, and the second winding is electrically connected with the second chip set; the magnetic element includes at least one of a coupled inductor, a non-coupled inductor, a planar transformer, and a foil-wound transformer.

Optionally, the chips in the first chip set are respectively disposed on the first side and the second side of the magnetic element, the chips in the second chip set are respectively disposed on the first side and the second side of the magnetic element, and the first side and the second side are disposed opposite to each other.

Optionally, the first chip set includes two first chips connected in series, the second chip set includes two second chips connected in series, a connection point of the two first chips connected in series is electrically connected to the first winding, and a connection point of the two second chips connected in series is electrically connected to the second winding.

Optionally, the passive element includes a multi-phase decoupling inductor, the multi-phase decoupling inductor includes a plurality of windings arranged side by side, the power module includes chips corresponding to the windings one by one, and the chips are electrically connected to the corresponding windings;

the chips electrically connected with the adjacent windings are arranged on the opposite sides of the multiphase decoupling inductor;

the center posts corresponding to the windings are arranged perpendicular to the pin outlet surfaces of the power supply modules, and the windings are wound back to the side surfaces of the chips and then electrically connected with the connecting pins.

Optionally, the passive element includes a multi-phase decoupling inductor, the multi-phase decoupling inductor includes a plurality of windings arranged side by side, the power module includes chips corresponding to the windings one by one, and the chips are electrically connected to the corresponding windings;

the chips are all arranged on the same side of the multiphase decoupling inductor;

the center post corresponding to each winding is arranged in parallel to the pin outlet surface of the power module, and the winding is bent and then electrically connected with the connecting pins on the opposite surface of the corresponding chip.

Optionally, the passive component includes a magnetic component, and a window direction of a magnetic core of the magnetic component is perpendicular to the pin-out surface of the power module, or a window direction of a magnetic core of the magnetic component is perpendicular to the terminal-out surface of the chip.

Optionally, the passive element includes at least one capacitor, and a length direction of the capacitor is perpendicular to the pin-out surface of the power module.

Optionally, the chip includes a back surface opposite to the terminal outlet surface, and a conductive line is connected between the back surface of the chip and the surface of the power module.

Optionally, the conductive traces are in contact with or electrically connected to the back surface of the chip through conductive vias, and the conductive traces are exposed on the surface of the power module; or

The conductive circuit is in contact with or electrically connected with the back surface of the chip, and the conductive circuit is connected with the surface of the power supply module through the conductive through hole.

Optionally, the surface of the power module is provided with a heat conducting column or a heat conducting plate.

Optionally, each of the chips comprises one switching element, a plurality of switching elements connected in parallel, or two switching elements connected in series;

the chip and the passive element form at least one of a buck circuit, a boost circuit, a buck/boost circuit, an LLC circuit, a switched capacitor circuit, a Cuk circuit and a flyback circuit.

According to the second aspect of the present invention, there is also provided a method for manufacturing a power module, including the steps of:

s100: stacking and packaging a passive element and a chip in a first packaging material, so that an included angle formed by the outgoing terminal surface of the chip and the stacking direction of the first packaging material is more than 45 degrees and less than 135 degrees, and the passive element is electrically connected with a chip terminal of the chip to form a power module connecting piece;

s200: cutting the power module connecting sheet along a first cutting surface to form a plurality of power modules, forming connecting pins by exposed conductive parts after cutting, and forming a first connecting layer between a pin outlet surface of each power module and the chip, wherein the first connecting layer is used for electrically connecting the connecting pins with at least one of chip terminals of the chip and the passive element;

in the formed power module, the projection of the chip on the pin outlet surface of the packaging material layer is not overlapped with the projection of the passive element on the pin outlet surface of the packaging material layer, and the included angle between the pin outlet surface of the chip and the pin outlet surface of the packaging material layer is larger than 45 degrees and smaller than 135 degrees.

Optionally, a first connection layer is formed in the first packaging material, and after the single power module is formed in step S200, the method further includes the following steps:

s300: packaging the power modules in a second packaging material, wherein terminal surfaces of the power modules are coplanar with each other, a second connecting layer is formed in the second packaging material layer, the second connecting layer is electrically connected with the first connecting layer, and an included angle formed by the first connecting layer and the second connecting layer is larger than 45 degrees and smaller than 135 degrees, so that a second power module connecting piece is formed;

s400: and cutting the second power module connecting piece along a second cutting surface to form a single power module.

Optionally, in step S300, after forming the second connection layer, packaging a chip on one side of the second connection layer.

Optionally, in step S100, the passive element includes at least one capacitor, and when the capacitor is encapsulated in the encapsulation material, a length direction of the capacitor is perpendicular to the first cutting surface, or a length direction of the capacitor is parallel to the first cutting surface.

Optionally, in step S100, the forming of the power module connection piece includes forming a passive component package connection piece by packaging the passive component, forming a chip package connection piece by the chip, welding the passive component package connection piece and the chip package connection piece, and electrically connecting the passive component and the chip to form the power module connection piece.

Optionally, in step S100, the forming of the power module connecting piece includes forming a passive component package connecting piece by packaging the passive component, and packaging the chip by using the passive component package connecting piece as a substrate to form the power module connecting piece;

or, the chip package forms a chip package connecting piece, and the chip package connecting piece is used as a substrate to package the passive element to form a power module connecting piece.

By adopting the power module, the chip and the passive element are arranged in a tiled manner, so that the power module with smaller height is easier to realize compared with a stacked structure. Because the chip is basically vertically arranged, the chip is more directly connected with the passive element, and the current impedance and the loss or parasitic inductance can be reduced; and because the chip is basically vertically arranged, the occupied area of the power module is favorably reduced, the structure is more compact, and the power density is higher. The upper surface and the lower surface of the power supply module are better in symmetry, so that heat dissipation paths are more conveniently and symmetrically arranged on the upper surface and the lower surface, or connecting pins are symmetrically arranged on the upper surface and the lower surface, and the like.

For a better understanding of the features and technical content of the present invention, reference should be made to the following detailed description of the present invention and accompanying drawings, which are included to illustrate and not limit the scope of the present invention.

Drawings

The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings.

FIG. 1 is a schematic diagram of an internal space of a data center according to the prior art;

FIG. 2 is a schematic diagram of an internal space of a mobile phone in the prior art;

fig. 3 and 4 are schematic structural diagrams of two stacked power modules in the prior art;

FIG. 5 is a side view of a power module of a first embodiment of the present invention;

FIG. 6 is a cross-sectional view taken in the direction A1-A1 of FIG. 5;

FIG. 7 is a cross-sectional view taken in the direction A2-A2 of FIG. 5;

FIG. 8 is a side view of a power module of a second embodiment of the present invention;

FIG. 9 is a cross-sectional view taken in the direction A3-A3 of FIG. 8;

FIG. 10 is a top view of a power module including an inductor according to a third embodiment of the present invention;

FIG. 11 is a top view of a power module including two inductors according to a third embodiment of the invention;

fig. 12 is a top view of four chips packaged in a power module according to a third embodiment of the present invention;

FIG. 13 is a side view of a power module of a fourth embodiment of the present invention;

FIG. 14 is a cross-sectional view taken in the direction A4-A4 of FIG. 13;

FIG. 15 is a side view of a power module of a fifth embodiment of the present invention;

FIG. 16 is a top view of a power module according to a fifth embodiment of the present invention;

FIG. 17 is a side view of a power module of a sixth embodiment of the present invention;

FIG. 18 is a top view of a power module of a sixth embodiment of the present invention;

fig. 19 is a side view of a power module of a seventh embodiment of the invention;

fig. 20 is a top view of a power module of a seventh embodiment of the present invention;

fig. 21 is a side view of a power module of an eighth embodiment of the invention;

fig. 22 is a top view of a power module of an eighth embodiment of the present invention;

FIG. 23 is a side view of a power module of a ninth embodiment of the invention;

fig. 24 is a top view of a power module of a ninth embodiment of the invention;

fig. 25 is a side view of a power module of a tenth embodiment of the invention;

fig. 26 is a top view of a power module of a tenth embodiment of the invention;

fig. 27 is a side view of a power module of an eleventh embodiment of the invention;

fig. 28 is a side view of a power module of a twelfth embodiment of the invention;

fig. 29 is a side view of a power module of a thirteenth embodiment of the invention;

fig. 30 is a side view of a power module of a fourteenth embodiment of the invention;

FIG. 31 is a sectional view taken in the direction A6-A6 of FIG. 30;

FIG. 32 is a cross-sectional view taken in the direction A7-A7 of FIG. 30;

fig. 33 is a side view of a power module of a fifteenth embodiment of the invention;

FIG. 34 is a sectional view taken in the direction A8-A8 of FIG. 33;

FIG. 35 is a sectional view taken in the direction A9-A9 of FIG. 33;

FIG. 36 is a schematic process diagram illustrating a first step of a method for manufacturing a power module according to the present invention;

FIG. 37 is a process diagram of a second step of a method for manufacturing a power module according to the present invention;

FIG. 38 is a process diagram of a third step of a method for manufacturing a power module according to the present invention;

FIG. 39 is a side view of an individual power module cut to form in a method of making a power module of the present invention;

FIG. 40 is a cross-sectional view taken in the direction A10-A10 of FIG. 39;

FIG. 41 is a schematic diagram illustrating a fourth step of the method for manufacturing a power module according to the present invention;

FIG. 42 is a process diagram of step five of the method for manufacturing a power module according to the present invention;

FIG. 43 is a side view of the single power module of FIG. 42;

fig. 44 is a schematic view showing a chip embedded in the second rewiring layer in the manufacturing method of the power module of the present invention;

FIG. 45 is a side view of the single power module of FIG. 44;

FIG. 46 is a process diagram of step one of another method of making a power module according to the present invention;

FIG. 47 is a process diagram of step two of another method for manufacturing a power module according to the present invention;

FIG. 48 is a schematic structural view of a power module formed by another method of manufacturing a power module according to the present invention;

FIG. 49 is a block circuit according to an embodiment of the present invention;

fig. 50 is a schematic diagram of a Boost circuit according to an embodiment of the invention;

FIG. 51 is a block/Boost circuit according to an embodiment of the present invention;

FIG. 52 is a schematic diagram of a four-switch buck-boost circuit according to an embodiment of the present invention;

FIG. 53 is a schematic diagram of an LLC circuit in accordance with an embodiment of the invention;

fig. 54 is a schematic diagram of a switched capacitor circuit according to an embodiment of the invention.

Reference numerals:

1 chip 5 wiring layer

11 chip terminal 5a first wiring layer

1a first chip 5b second wiring layer

1b second chip 52 conductive vias

1c third chip 53 conductive traces

1d fourth chip 54 copper column

2 passive component 6 connecting pin

21 first connecting pin of capacitor 61

211 first capacitor 62 second connection pin

212 second capacitor 71 Heat conduction plate

22 inductor 72 radiator

22a first winding 73 carries the chip

22b second winding 74 data center motherboard

221 upper side column 75 module shell

222 lower edge column 76 display screen

223 center pillar 77 battery

78 mobile phone shell of 23 transformer

231 first cover 79 mobile phone main circuit board

232 second cover plate 8 circuit board

233 magnetic core 91 first rewiring layer

234 mounting groove 92 cutting surface

24 second rewiring layer for peripheral devices 93

3 connection layer 100 power module

35 welding spot

4 insulating packaging material

41 first encapsulating material

42 second encapsulant

Detailed Description

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.

In the description of the present invention, it is to be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.

In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.

In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.

In order to solve the technical problems in the prior art, the invention provides a power module, which comprises a chip, a passive element and a connecting pin arranged on a pin outlet surface of the power module, wherein a chip terminal is arranged on the pin outlet surface of the chip, the passive element is electrically connected with the chip terminal of the chip, and the connecting pin is electrically connected with at least one of the chip terminal of the chip and the passive element. The passive elements may include at least one of an inductor, a capacitor, and other passive devices, and the number of passive elements may be one or more. The projection of the chip on the pin outlet surface of the power module is not overlapped with the projection of the passive element on the pin outlet surface of the power module, namely the overlapping area of the projection of the chip on the pin outlet surface of the power module and the projection of the passive element on the pin outlet surface of the power module is 0, so that a power module structure with the chips and the passive elements laid flatly is formed, and compared with a stacked structure, the power module with smaller height is easier to realize. In the embodiment, the included angle between the outgoing terminal surface of the chip and the outgoing pin surface of the power module is greater than 45 degrees and smaller than 135 degrees, namely, the chip is basically vertically arranged in the power module, so that the chip is more directly connected with a passive element, and the current impedance and the loss or parasitic inductance can be reduced; because the chip is basically vertically arranged, the occupied area of the power module is favorably reduced, the structure is more compact, and the power density is higher.

Several embodiments of the power module of the present invention are described in detail below with reference to several embodiments of fig. 5-35.

Fig. 5 to 7 are schematic structural diagrams of a power module according to a first embodiment of the invention. The power module comprises a chip 1 and a passive element 2 (not shown), wherein the passive element comprises an inductor 22 and a capacitor 21, the chip 1 and the passive element are packaged by a packaging material 4 to form the power module, at least one side of the power module forms a pin surface, and a connecting pin 6 (not shown) is arranged on the pin surface. The chip 1 and the passive element are electrically connected through the wiring layer 5, and the chip terminal 11 of the chip 1 is electrically connected to the winding 22a of the inductor 22 and the capacitor 21 through the wiring layer 5. A connection layer 3 is disposed between the chip 1 and the pin-out surface of the power module, and the connection layer 3 electrically connects at least one of the chip 1, the inductor 22 and the capacitor 21 to the connection pin 6. The chip 1 is substantially vertically disposed relative to the lower surface of the power module, that is, the angle between the outgoing terminal surface of the chip 1 and the outgoing pin surface of the power module is greater than 45 ° and less than 135 °. For example, the angle between the outgoing terminal surface of the chip 1 and the outgoing pin surface of the power module is 90 °, that is, the outgoing terminal surface of the chip 1 is perpendicular to the outgoing pin surface of the power module. In addition, the chip 1, the inductor 22 and the capacitor 21 are tiled, and the projection of the chip 1 on the pin-out surface of the power module is not overlapped with the projection of the inductor 22 and the capacitor 21 on the pin-out surface of the power module, that is, the chip 1, the inductor 22 and the capacitor 21 are located on different vertical surfaces relative to the pin-out surface of the power module. The insulating encapsulant 4 is used to support and protect the chip 1 and passive components such as the inductor 22 and the capacitor 21, and can realize a three-dimensional structure of the circuit layer 5 and the connection layer 3.

By adopting the structure as shown in fig. 5 to 7, the length or width dimension of the outgoing terminal face of the chip 1 substantially determines the height of the entire power module package. In an alternative embodiment, the connection pins 6 may be respectively disposed on both side surfaces of the power module, for example, as shown in fig. 7, which is a cut-away schematic view a2-a2 of fig. 5, and at the same time, a change is made on the basis of fig. 5, that is, the second connection pin 62 and the first connection pin 61 are respectively disposed on the upper surface and the lower surface of the power module, so as to form a double-sided pin (pin) structure of the power module, and the connection layer 3 for connecting the connection pins 6 and the chip 1 may be respectively disposed between the first connection pin 61 or the second connection pin 62 and the chip 1. In this way, this power module may become a power module in which the connection pins 6 are provided on both side surfaces, and a structure in which the connection pins on both side surfaces are symmetrically provided may be implemented in some embodiments. In alternative embodiments, the connection Layer 3 in fig. 5 may include a conductive via, a Re-Distribution Layer (RDL), a conductive line on the same Layer as the connection pin 6, or the like.

Fig. 8 and 9 show schematic structural views of a power module of a second embodiment of the present invention. In this embodiment, the passive element includes an inductor 22 and two sets of capacitors, where the two sets of capacitors refer to the first capacitor 211 and the second capacitor 212, and the chip 1, the inductor 22, the first capacitor 211, and the second capacitor 212 are all disposed in a tiled manner, that is, a projection of the chip 1 on the pin-out surface of the power module is not overlapped with a projection of the inductor 22, the first capacitor 211, and the second capacitor 212 on the pin-out surface of the power module.

As shown in fig. 8, on the basis of the first embodiment, a first capacitor 211 may be further disposed on the left side of the chip 1. Thus, the power supply module of this second embodiment can be used to implement a variety of circuits, such as the Buck circuit shown in fig. 49. The first capacitor 211 arranged on the left side of the chip 1 in fig. 8 may be the input capacitor Cin of the Buck circuit shown in fig. 49, and the chip 1 includes a half-bridge circuit, i.e. includes two switches connected in series, and a connection point (e.g. SW1 or SW2 in fig. 49) between the switches connected in series is electrically connected to the winding 22a of the inductor 22. The inductor 22 may be arranged on the right side of the chip 1.

In fig. 9, the outgoing terminal surface of the chip 1 where the chip terminal 11 is located faces the inductor 22, and in other alternative embodiments, the outgoing terminal surface of the chip 1 where the chip terminal 11 is located may also be arranged opposite to the inductor 22. A second capacitor 212 is provided at the right side of the inductor 22 or at the output end of the inductor 22, and the second capacitor 212 may be the output capacitor Co of the Buck circuit shown in fig. 49. In addition, other peripheral devices 24 may also be tiled. In the perspective of fig. 8, connection pins, such as a first connection pin 61 and a second connection pin 62, are provided on both upper and lower surfaces of the power supply module. In addition, the circuit layer 5 may be disposed on both upper and lower sides or the periphery of the chip 1, and the chip terminal 11 of the chip and the first capacitor 211 may be electrically connected by bypassing the chip 1. In this embodiment, the circuit layer 5 cooperates with the connection layer 3 to realize the interconnection among the chip 1, the passive component 2 and the connection pins. The multi-path electric connection adopted in the embodiment can reduce the resistance and the parasitic inductance, and is beneficial to improving the efficiency and the dynamic performance. And the connecting pins, such as bonding pads, can be symmetrically arranged on the upper surface and the lower surface, so that the application is convenient.

Fig. 10 to 12 are schematic structural diagrams of a power module according to a third embodiment of the invention. This embodiment is different from the second embodiment in that a plurality of chips can be packaged in one power supply module. In some applications, multiple chips may be operated in parallel to allow the power module to achieve higher current or higher power. Fig. 10, 11, and 12 are top views and respectively show three alternative configurations of a power module in which a plurality of chips are provided. It should be noted that there is no overlap in the projections of the chips on the pin-out faces of the power modules.

In fig. 10, the power supply module includes two chips: the first chip 1a and the second chip 1b, and the first chip 1a and the second chip 1b may have a switching element, respectively, and the connection points of the first chip 1a and the second chip 1b are electrically connected to the first winding 22a of the inductor 22. In an alternative embodiment, in fig. 10, each of the first chip 1a and the second chip 1b may include a half-bridge circuit, and SW terminals of the two half-bridge circuits (i.e., connection points of upper arm switch tubes and lower arm switch tubes in the half-bridge circuit) are electrically connected to the first winding 22a of the inductor 22 after being short-circuited with each other, so as to achieve a larger output current. In this embodiment, the first chip 1a and the second chip 1b may be in a "face-to-face" arrangement, i.e., the outgoing terminal face of the first chip 1a and the outgoing terminal face of the second chip 1b are arranged toward each other. The first capacitor 211 can be arranged between the two chips and used as an input capacitor, and the electric connection circuit between the first capacitor 211 and the first chip 1a and the second chip 1b can be set to be shorter, so that the resistance and parasitic inductance between the first capacitor 211 and the first chip 1a and the second chip 1b can be reduced, the efficiency and the dynamic performance are improved, the structure is compact, and the power density is high. It should be noted that the terminal face of the chip in the present invention refers to the face from which the power terminal of the chip is led out, and in the chip containing a planar device, the terminal face refers to the face on which the chip terminal 11 is disposed; in a chip including a vertical device, the output terminal surface is a surface on which a gate electrode or an electrode for controlling switching is provided.

In fig. 11, the power supply module includes two chips: a first chip 1a and a second chip 1 b. In this embodiment, both the first chip 1a and the second chip 1b include a half bridge circuit. The power module includes two inductive windings: a first winding 22a and a second winding 22 b. The connection points of the upper and lower switching tubes of the two half-bridge circuits, i.e. the SW terminals, are electrically connected to two inductor windings, respectively, for example, the SW terminal of the first chip 1a is electrically connected to the first winding 22a, and the SW terminal of the second chip 1b is electrically connected to the second winding 22b, and the two inductors may be two independent inductors or a magnetic integrated structure as shown in fig. 11. Through adopting this kind of structure, can be in a power module encapsulation have a plurality of Buck circuits, can realize the simple parallelly connected or crisscross parallelly connected of a plurality of Buck circuits to reduce the output ripple when doing benefit to the lifting power, and promote power density.

In fig. 12, the power supply module includes four chips: the power module comprises a first chip 1a, a second chip 1b, a third chip 1c and a fourth chip 1d, wherein no other devices are arranged among the four chips so as to make the structure of the power module more compact. In this embodiment, the first chip 1a, the second chip 1b, the third chip 1c, and the fourth chip 1d are sequentially arranged in a row. Specifically, the output terminal surface of the second chip 1b and the output terminal surface of the third chip 1c are arranged to face each other, and the output terminal surface of the first chip 1a and the output terminal surface of the fourth chip 1d are arranged to face each other. This allows for higher power current output capability in a compact and compact volume. In other possible embodiments, the arrangement of the four chips and the orientation relationship of the terminal surfaces may be different.

Fig. 13 and 14 are schematic structural views showing a power module according to a fourth embodiment of the present invention. In this embodiment, the power supply module comprises two chip sets, each chip set comprises at least one chip, and the outgoing terminal surfaces of the two chip sets are arranged in a face-to-face manner; at least one passive element is arranged between the outgoing terminal surfaces of the two chip sets. Specifically, each chip set may include two chips, such as a first chip 1a and a second chip 1b constituting one chip set, and a third chip 1c and a fourth chip 1d constituting another chip set. In the view of fig. 14, the outgoing terminal face of the first chip 1a and the outgoing terminal face of the second chip 1b are both disposed toward the right; the outgoing terminal face of the third chip 1c and the outgoing terminal face of the fourth chip 1d are both disposed toward the left. The power supply module also comprises a counter-coupling inductor 2 and a plurality of capacitors, wherein the inductor 2 is positioned between the outgoing terminal surfaces of the two chip sets. The second chip 1b is electrically connected to the first winding 22a, the fourth chip 1d is electrically connected to the second winding 22b, and the second chip 1b and the fourth chip 1d may have half-bridge circuits, respectively. The first chip 1a and the third chip 1c may have half-bridge circuits, respectively, and the SW terminal of the chip 1a is also electrically connected to the first winding 22a, and the SW terminal of the chip 1c is also electrically connected to the second winding 22 b. The structure of the power module employing four chips shown in fig. 13 and 14 can further increase the current output capability compared to the structure in which only the second chip 1b and the fourth chip 1d are connected to the winding. Further, in this embodiment, if the four chips 1a, 1b, 1c, and 1d are all single switches or parallel-connected switches, the first chip 1a and the second chip 1b may be connected in series to electrically connect the SW terminal to the first winding 22a, and the third chip 1c and the fourth chip 1d may be connected in series to electrically connect the SW terminal to the second winding 22b, and the specific connection manner may be flexibly applied as required. In addition, the arrangement structure of the power supply module of the embodiment can shorten the current transmission distance, improve the transmission efficiency, flexibly form the counter-coupling power module and has high power density.

Fig. 15 and 16 show schematic structural views of a power supply module of a fifth embodiment of the present invention. The power module comprises two chips: the multi-phase buck circuit comprises a first chip 1a and a second chip 1b, wherein the two chips respectively comprise a half-bridge circuit, the SW terminal of the first chip 1a is connected with a first winding 22a of an inductor 22, the SW terminal of the second chip 1b is connected with a second winding 22b of the inductor 22, and the first winding 22a and the second winding 22b are vertically penetrated through the same window of the inductor 22 through the upper surface of the inductor 22 to be electrically connected with a connecting pin 6 of a power module on the lower surface of the power module, so that the multi-phase buck positive coupling circuit can be formed. This embodiment is further different from the previous embodiments in that the window direction of the magnetic core of the inductor of the previous embodiments is a horizontal direction, i.e. the window axis of the inductor 22 is parallel to the direction of the lead-out surface of the power module. And the window direction of the magnetic core of the inductor in the fifth embodiment is a vertical direction, that is, the window axis of the inductor is perpendicular to the direction of the pin-out surface of the power supply module. The window direction makes the magnetic core of inductance be a whole in the direction of height for vertical direction, does not need a plurality of magnetic path promptly to pile up the setting, more does benefit to the height that reduces the inductance. Because the thickness of the magnetic core needs to be greater than or equal to the minimum limit thickness due to the requirement for strength, if the magnetic core structure of the fourth embodiment is adopted, the thickness of the magnetic core in the height direction needs to be twice as large as the minimum limit thickness; and in the fifth embodiment, the thickness of the magnetic core in the height direction may be twice the minimum limit thickness.

Fig. 17 and 18 are schematic structural views of a power module according to a sixth embodiment of the present invention. This embodiment differs from the fifth embodiment in that the window of the inductor 22 is horizontally arranged, i.e. the window axis of the inductor 22 is parallel to the pin-out face of the power module, the first chip 1a and the second chip 1b are respectively arranged at both ends of the window of the inductor 22, the SW terminal of the first chip 1a is connected to the first winding 22a and connected to the connection pin 6 on the left side of the inductor, and the SW terminal of the second chip 1b is connected to the second winding 22b and connected to the connection pin 6 on the right side of the inductor. In this embodiment, the passive element further comprises a capacitor 21, and the capacitor 21 may be an input capacitor or an output capacitor. The structure of the power module of the embodiment can form a two-phase or multi-phase decoupling power module, such as a two-phase decoupling buck module, the structure is simple and compact, the symmetry of two-phase circuit parameters is good, and the parallel output capability and the dynamic property of a multi-phase circuit are favorably improved, and the power density is better.

Fig. 19 and 20 are schematic structural views of a power module according to a seventh embodiment of the present invention. This embodiment differs from the previous embodiments in that the passive components in the power module comprise a transformer 23, and the substantially vertically arranged chip 1 and the transformer 23 are arranged in a tiled manner within the package 4. The power supply module of this embodiment may be used to form an LLC circuit as shown in fig. 53, but is not limited thereto. Taking the circuit shown in fig. 53 as an example, the first chip 1a in fig. 19 may be a primary side switching device, and the second chip 1b may be a secondary side switching device; in other embodiments, the first chip 1a may also be a secondary side switching device, and the second chip 1b is a primary side switching device. The first chip 1a and the second chip 1b are disposed on the periphery of the transformer, as shown in fig. 19 on the left and right sides of the transformer 23. In other alternative embodiments, the chips 1 (not shown) may be disposed on all four sides of the transformer 23. The transformer 23 may be encapsulated in an insulating second encapsulating material 42, and the second encapsulating material 42 encapsulating the transformer 23 may be the same as or different from the insulating first encapsulating material 41 around the chip 1. In some embodiments, the first encapsulant material 41 used to encapsulate the power module may be FR4, ABF, or other encapsulant material for an embedded (embedded) process, and the second encapsulant material 42 used to encapsulate the transformer 23 may be various molding (molding) materials that can be encapsulated using a molding process. This correspondingly entails that the insulating encapsulating material in the connection layer 3 can be composed of a plurality of materials. In other embodiments, the first encapsulant 41 may also be various molding compounds (molding compounds), and the second encapsulant encapsulating the transformer 23 may also be FR4, ABF or other encapsulant using an embedding process, so that various processes can be flexibly adopted for encapsulation, which is beneficial to structure optimization and cost reduction. In addition, can all set up the articulamentum between power module's upper and lower surface and chip, form two-layer articulamentum promptly, be convenient for walk the line simultaneously between chip and power module's upper and lower surface, and can set up connecting pin simultaneously at the upper and lower surface of packaging body.

This embodiment can be implemented using a variety of processes. For example, the transformer 23 may be first encapsulated with the second encapsulating material 42 and then encapsulated with the chip again; or the first chip 1a and the second chip 1b arranged on the left side and the right side respectively form packaging substrates, and then after being welded with a transformer in the middle, the packaging substrates are formed by injecting (molding) insulating packaging materials between the left packaging substrate and the right packaging substrate; alternatively, the transformer 23 may be packaged by the second packaging material 42, terminals may be disposed on two or more sides, the first chip 1a and the second chip 1b on the left and right sides respectively form a packaging substrate, and terminals may be disposed on the surface of the packaging substrate, and then the left and right sides of the package formed by the transformer 23 may be respectively connected to the packaging plates formed by the first chip 1a and the second chip 1b on the left and right sides respectively by terminal welding, thereby forming the final power module. Of course, if the power module is produced in a continuous sheet (panel), the power module may be cut to form a final power module, and if necessary, other post-treatments may be performed, such as cleaning or forming an anti-oxidation layer. This structure can form a power module including a transformer, such as the power module of the circuit shown in fig. 52 or fig. 53, which is small in height and high in efficiency. In addition, the connection layer 3 in the embodiment can be realized by adopting various process modes, and is simple, flexible and convenient to apply. The transformer 23 in fig. 19 and 20 is a foil-wound transformer (foil-wound transformer), which is advantageous for forming a small-volume, high-current structure. In other embodiments, the transformer may be a planar transformer, similar to the transformer of fig. 21, using traces in the PCB as windings, leaving holes in the PCB for mounting the magnetic cores.

Fig. 21 and 22 are schematic structural diagrams of a power module according to an eighth embodiment of the present invention. This embodiment differs from the seventh embodiment in that the primary winding and the secondary winding of the transformer 23 can be formed in the insulating packaging material 4 first, like a planar transformer, by a process such as a PCB process, and then electrically connected to the embedded vertically arranged chip 1. After forming a mounting groove 234 in the package body, the core 233 is placed into the mounting groove 234, so that the winding is sleeved on the core 233, and finally the complete transformer 23 and the complete power module are formed. The number of the magnetic cores 233 may be 2 or more, and the first cover plate 231 and the second cover plate 232 connect the plurality of magnetic cores 233 to form a closed magnetic circuit. The magnetic pillar 233, the first cover plate 231, and the second cover plate 232 are all made of a magnetic conductive material, and the magnetic core 233 may be integrated with one of the cover plates 231 or 232 in advance. Namely, the transformer winding can be packaged with the first chip 1a and the second chip 1b in advance, a window for installing the magnetic core 233 is reserved, and the magnetic core 233 is placed into the window to form the power module. Therefore, the magnetic material can be prevented from being embedded in the packaging material 4, and the magnetic material is prevented from being influenced by stress to affect the efficiency or reliability. And the structure is simple and compact, and the power density is high. Of course, the transformer 23 in fig. 21 and 22 may also be a coupled inductor or foil wound transformer in some embodiments, or the inductor 22 may be formed in a similar manner instead of the transformer 23.

Fig. 23 and 24 are schematic structural views of a power module according to a ninth embodiment of the present invention. In this embodiment, the passive component includes a capacitor 21, the chip 1 and the capacitor 21 are disposed in a tiled manner, the capacitor 21 may be a discrete device or an entire capacitor plate, a plurality of chips are disposed around the capacitor 21, or the capacitors are disposed around the chips, or the capacitors are alternately disposed. The power supply module with the structure can be used for realizing circuits with special topologies, such as a switched Capacitor Circuit (Switching Capacitor Circuit). There are many specific switched capacitor circuit topologies, only one of which is shown in fig. 54. The topology of fig. 54 will be described as an example. The capacitor of the ninth embodiment may be the capacitor 21 in fig. 54, the input capacitor Cin, or the output capacitor Co. The switches Q1-Q4 in fig. 54 may be implemented by the first chip 1a, the second chip 1b, or the third chip 1c in the ninth embodiment. For example, the first chip 1a includes a switch Q1, the second chip 1b includes a switch Q2, and the third chip 1c includes a switch Q3 and a switch Q4, and the switch Q3 and the switch Q4 are connected in series to form a half-bridge structure. The capacitor 21 of fig. 24 may be the capacitor 21 of fig. 54, and the first chip 1a, the second chip 1b, and the third chip 1c are electrically connected to the capacitor 21 through the wiring layer 5. Of course, if the switch Q1 and the switch Q2 are implemented by using the same chip, the power supply module of this embodiment may include 2 chips; if the switches Q1-Q4 are implemented as separate chips, the module in this embodiment may contain four chips inside. This means that the number of chips in the module is related to the way the switching devices in the circuit topology are implemented. Adopt this embodiment can form switched capacitor power module, through choosing for use the electric capacity that height and chip lead-out terminal surface length or width are equivalent, can realize high space utilization, under the high equivalent condition of electric capacity of module height, because the chip erects and reduces module area and volume, promotes power module's power density.

The connection layer 3 in fig. 23 may be located between the chip and the lower surface of the power module, or between the chip and the upper surface of the power module, and here, the connection layer is described as being located between the chip and the lower surface of the module, that is, a range indicated by a dashed line box in the drawing. The connection layer 3 includes a metal wiring layer in a horizontal direction and a connection structure between the wiring layers, like a trace layer (trace) in a PCB. The metal wiring layers in the connection layer 3 (also similar to traces in a PCB or traces formed by metallization methods such as electroplating) are arranged in a direction parallel to the lower surface of the power supply module. As can be seen from fig. 23, the wiring layer 5 includes a metal wiring layer in the vertical direction and a connection structure between the wiring layers, and specifically, the metal wiring layer in the wiring layer 5 may be arranged in a direction parallel to the outgoing terminal surface of the chip 1, that is, perpendicular to the outgoing pin surface of the power supply module. Due to the difference in manufacturing processes, the cross section of the metal wiring layer is generally square or rectangular, and the connection structure between the wiring layers is generally made by a process such as via hole, and thus the cross section structure is generally truncated cone-shaped. The metal wiring layer in the circuit layer 5 and the metal wiring layer in the connecting layer 3 can be arranged in a mutually perpendicular mode, so that the structure of the wiring mutually perpendicular arrangement in the same packaging module is integrally realized, more complex wiring arrangement is facilitated, the power density of a lifting system is facilitated, and the efficiency of a power supply module is facilitated.

Fig. 25 and 26 are schematic structural views of a power module according to a tenth embodiment of the present invention. The embodiment is different from the ninth embodiment in that the capacitor 21 in the power module can be set up vertically, that is, the length direction of the capacitor (i.e., the direction of the largest dimension of the three-dimensional dimensions of the capacitor) is perpendicular to the pin-out surface of the power module, for example, for a small-package capacitor, the height of the capacitor is much smaller than that of a chip, and the capacitor can be set up vertically to match the height of the chip, so that the arrangement can reduce the floor area of the power module and improve the power density. In addition, in other alternative embodiments, the two pole terminals of the standing capacitor can be more conveniently connected with the pins of the chip 1, so that the length of a connecting line is reduced, and the resistance and parasitic inductance of the power module are reduced.

Fig. 27 is a side view of a power module of an eleventh embodiment of the invention. This embodiment is different from the foregoing embodiment in that a conductive line 53 is further provided on the back surface (the surface opposite to the outgoing terminal surface) of the chip 1, and the conductive line 53 may be in contact with the back surface of the chip 1 through a conductive via 52 and exposed at the edge of the power supply module, for example, at the left side of the power supply module in fig. 27. So set up and to realize that 1 heat of chip conducts the surface of power module fast, do benefit to 1 heat dissipation of chip. In some other alternative embodiments, it is also possible that the conductive traces 53 are in contact with the back surface of the chip 1 and are connected to the surface of the power module through conductive vias 52, facilitating the conduction of heat from the chip 1 to the surface.

Fig. 28 is a schematic structural diagram of a power module according to a twelfth embodiment of the present invention. The difference between this embodiment and the foregoing embodiment is that a copper pillar 55 may be further disposed on the surface of the power module, and the copper pillar 55 may increase the surface area to facilitate heat dissipation. For example, the power module shown in fig. 28 may be soldered to the circuit board 8 and then cooled by blowing air, or the power module may be immersed in an insulating cooling liquid to accelerate heat dissipation, and the cooling liquid may be circulated to further increase the heat dissipation rate.

As shown in fig. 29, which is a schematic structural diagram of a power module according to a thirteenth embodiment of the present invention, a plurality of power modules are soldered to a circuit board 8, and a heat conducting plate 71 is disposed between the power modules, and the heat conducting plate 71 may be in contact with an adjacent power module, or a heat conducting silicone grease or a heat conducting pad may be disposed between the heat conducting plate 71 and the power modules to facilitate heat conduction. The heat conductive plate 71 is in contact with the heat sink 72. Heat is transferred to the air or other heat-dissipating medium through the heat sink 72.

Fig. 30 to 32 are schematic structural views of a power module according to a fourteenth embodiment of the invention. This embodiment differs from the previous one in that the passive element comprises an inductor 22 and that the inductor 22 is a polyphase counter-coupled inductor, for example a 4-phase counter-coupled inductor 22 as shown in fig. 30-32. The power module includes 4 chips: a first chip 1a, a second chip 1b, a third chip 1c and a fourth chip 1d, each of which comprises a series connection of half-bridge structures. The inductor 22 includes four center pillars 223, an upper pillar 221, and a lower pillar 222 arranged side by side. The center pillar 223 has one end connected to the upper pillar 221 and the other end connected to the lower pillar 222. One winding 22a is provided on each center pillar 223, and one end of each winding 22a is electrically connected to the SW terminal of one chip. The center posts 223 corresponding to the windings 22a are vertically arranged, and the windings 22a are wound back to the side surface of the chip and then lead out pins, that is, the other end of each winding 22a is electrically connected with the connecting pin 6 of the power module. The chips 1a, 1b, 1c, 1d are arranged substantially vertically and are arranged with the inductor 22 lying flat against each other, the chips 1a, 1b, 1c, 1d being arranged alternately on both sides of the inductor 22, in other words, the chips electrically connected to adjacent windings 22a are arranged on different sides, e.g. opposite sides, of the polyphase decoupling inductor. For example, the first chip 1a and the second chip 1b are disposed on one side of the inductor 22, and the third chip 1c and the fourth chip 1b are disposed on the other side of the inductor 22. In fig. 30, the circles on the right side of the center pillar 223 corresponding to each of the winding 1a and the winding 1b are marked by x, which indicates that current is transmitted inward in the vertical paper, and the circles on the left side of the center pillar 223 corresponding to each of the winding 1a and the winding 1b are marked by dot, which indicates that current is transmitted outward in the vertical paper. The embodiment can realize multiple opposite coupling power supply modules, can realize higher power density and higher dynamic performance, and the chip is directly connected with the inductance winding, so that the connection distance between the chip and the inductance is shortened, and the realization of higher efficiency is facilitated.

Fig. 33 to 35 are schematic structural diagrams of a power module according to a fifteenth embodiment of the invention. This embodiment differs from the fourteenth embodiment in that the four chips 1a, 1b, 1c, 1d are all arranged on the same side of the inductor 22, and one end of the winding of each inductor 22 is electrically connected to the corresponding chip on one side of the inductor 22, and the other end can be led out from the other side of the inductor 22 and connected to the connection pin 6 of the power supply module. The middle columns 223 are horizontally arranged, one end of each middle column is connected with the upper column 221, the other end of each middle column 223 is connected with the lower column 222, each winding is bent below the upper column 221 and above the lower column 222 to bypass the corresponding middle column 223, and then pins are led out below the lower column 222 and on the opposite side of the corresponding chip, namely the other end of each winding is electrically connected with the connecting pin 6 of the power module. The structure enables the customer application to be more convenient, the structure is simple and compact, the method has the advantages of being beneficial to achieving higher power density and higher dynamic performance, the chip is directly connected with the inductance winding, the connection distance between the chip and the inductance is shortened, and the method is beneficial to achieving higher efficiency.

The invention also provides a preparation method of the power module, which comprises the following steps:

s100: stacking and packaging a passive element and a chip in a first packaging material, so that an included angle formed by a terminal surface of the chip and the direction of the first packaging material accumulation is larger than 45 degrees and smaller than 135 degrees, a first rewiring layer is formed on one side of the chip or the passive element, and the passive element is electrically connected with a chip terminal of the chip to form a power module connecting piece;

s200: cutting the power module connecting sheet along a first cutting surface to form a plurality of power modules, forming connecting pins by exposed conductive parts after cutting, and forming a first connecting layer between a pin outlet surface of each power module and the chip, wherein the first connecting layer is used for electrically connecting the connecting pins with at least one of chip terminals of the chip and the passive element;

in the formed power module, the projection of the chip on the pin outlet surface of the packaging material layer is not overlapped with the projection of the passive element on the pin outlet surface of the packaging material layer, and the included angle between the pin outlet surface of the chip and the pin outlet surface of the packaging material layer is larger than 45 degrees and smaller than 135 degrees.

Therefore, in the power module obtained by the preparation method of the power module, because the chip and the passive element are arranged in a tiled manner, the power module with smaller height is easier to realize compared with a stacked structure; because the chip is basically vertically arranged, the chip is more directly connected with the passive element, the current impedance and the loss or the parasitic inductance can be reduced, and the vertical arrangement of the chip is favorable for reducing the occupied area of the power module, so that the structure is more compact and the power density is higher.

The following describes specific embodiments of a method for manufacturing a power module in several embodiments in detail with reference to fig. 36 to 48.

Fig. 36 to 40 are schematic process diagrams illustrating a method for manufacturing a power module according to the present invention.

In this embodiment, as shown in FIGS. 36 to 38, it corresponds to the above-mentioned specific implementation of S100. As shown in fig. 36, first, the passive element 2 is embedded in the insulating packaging material 4, the passive element may be an inductor, or certainly, a capacitor or other passive elements, and may also be a plurality of passive elements arranged in an array to form a connection sheet (panel), then as shown in fig. 37, one or more first redistribution layers 91 are formed on the surface of the connection sheet in which the passive elements are embedded, and the chip 1 is embedded, the chip 1 may be flip-chip bonded to the first redistribution layer 91, for example, the chip 1 is bonded to the first redistribution layer 91 through the bonding point 35 in fig. 37, so that the angle formed by the outgoing terminal surface of the chip and the direction in which the first packaging material is stacked is greater than 45 °, smaller than 135 °, for example, may be 90 °; then, other rewiring layers and other embedded passive components or other chips can be formed on the surface of the connecting piece, and other devices such as capacitors can be welded on the corresponding welding points by adopting a welding mode, as shown in fig. 38. The first rewiring layer 91 formed here may serve as the connection layer 3 or the line layer 5 in the power supply module.

Then, the specific implementation manner of step S200 is performed, that is, the continuous piece is cut into individual modules along the cutting surface 92, the exposed conductive portions after cutting form connection pins, and a connection layer is formed between the pin-out surface of the power module and the chip 1, and the connection layer is used for electrically connecting the connection pins to at least one of the chip terminals of the chip and the passive components. Fig. 39 is a side view showing a single power module formed after step S200, and fig. 40 is a sectional view showing a direction a10-a10 in fig. 39. In other alternative embodiments, the chip may be embedded first in step S100, or the chip and the passive component may be embedded at the same time, and then the passive component is embedded, and then other chips may be embedded continuously. The power module with the chips basically vertically arranged and the chips and other passive elements flatly arranged can be realized by the preparation method, the spatial three-dimensional arrangement of the circuits in the module can be easily realized, the process is simple, and the module cost is favorably reduced.

Fig. 41 shows that step S300 is continued in addition to step S200. As shown in fig. 41, a plurality of power supply modules as shown in fig. 39 are embedded in an insulating encapsulating material 4. Then, as shown in fig. 42, a second rewiring layer 93 is formed on the lower side of the power supply module shown in fig. 41, and the second rewiring layer 93 electrically connects the first rewiring layer 91 with the connection pins of the lower surface of the power supply module shown in fig. 42, or realizes interconnection between different wires of the first rewiring layer 91. The web is then cut along cutting surface 92 into individual modules, a side view of which is illustrated in fig. 43. The second rewiring layer 93 here may also serve as the connection layer 3 or the wiring layer 5 in the power supply module. In this embodiment, the first re-wiring layer 91 and the second re-wiring layer 93 below the chip 1 form the connection layer 31; similarly, a connection layer 32 may also be formed thereover. In addition, in some embodiments, a second redistribution layer may also be formed on the upper surface of the connection piece in step S300, so that multi-layer interconnection of circuits may be achieved, which is beneficial to improving efficiency and dynamic performance of the power module, and connection pins may also be arranged on the upper surface to achieve double-sided arrangement of connection pins for the power module. The heat conduction of the chip or other devices to the upper surface is facilitated, and the heat dissipation is facilitated. The process shown in fig. 41 to 43 can be used for realizing the free arrangement of the power module connecting pins 6 on the lower surface or the upper surface, thereby facilitating the application of customers. In addition, a rewiring layer structure which is perpendicular to each other can be realized, for example, the first rewiring layer 91 and the second rewiring layer 93 are perpendicular to each other, so that a more complex space three-dimensional circuit network can be easily realized, more compact and dense current transmission can be realized, and a power module with higher power density can be realized.

As shown in fig. 44, the difference from the process shown in fig. 41 to 43 is that a chip 1 is further embedded in the second redistribution layer 93, and this chip may be the same as or different from the embedded chip shown in fig. 36 to 39. Of course, the chip 1 may be embedded in the second rewiring layer on the upper side of the power module. The power module shown in fig. 45 is formed after cutting along the cutting surface. That is, the chip can be embedded in the connection layer. By adopting the process, the power supply module with a plurality of chips vertically arranged can be realized, and the power supply module with more complexity and higher power density can be realized.

Fig. 46 to 48 are schematic views illustrating another method for manufacturing a power module according to the present invention. This method differs from the foregoing embodiment in that the first rewiring layer 91 may be formed by embedding the chip 1 in an insulating encapsulating material as shown in fig. 46, and of course, the second rewiring layer 93 may be provided above the chip 1. Then, as shown in fig. 47, other passive components are further integrated, for example, if the inductor 22 is further embedded below, the winding of the inductor 22 is electrically connected to the chip 1, for example, if a half-bridge circuit is included in the chip 1, one end of the winding of the inductor 22 may be electrically connected to the SW terminal of the chip 1; the capacitor 21 may be embedded continuously above the chip 1, for example, as an input capacitor of the chip 1, and another capacitor 21 may be embedded below the inductor 22, for example, as an output capacitor. The chip 1 and the inductor winding may also be connected by means of a solder joint 35, for example by means of soldering. In other embodiments, the capacitor 21 on the chip 1 and the capacitor 21 under the inductor 22 may also be electrically connected to the corresponding redistribution layer using the solder 35. Such a manner is favorable for the electrical connection between the chip 1 and the rewiring layer, for example, the electrical connection can be performed in a metallization manner, which can more easily realize the electrical connection of a complex circuit and is also favorable for improving the reliability of the chip 1. Meanwhile, in fig. 47, the continuous piece may be cut along the cutting surface 92 to form the power module shown in fig. 48. In addition, by arranging the length direction of the capacitor perpendicular to the cutting surface, after the connecting piece is cut along the cutting surface 92, the capacitor 21 in the formed power module is in a vertical state, that is, the capacitor 1 shown in fig. 48 is vertically arranged in the power module. The posture of the capacitor in the power module package can be flexibly adjusted according to the length of the capacitor, and the capacitor is transversely placed or vertically placed as shown in fig. 48. Simple process and high production efficiency.

It should be noted that the cutting surface 92 may be parallel to or coincident with the pin-out surface of the power module, and an included angle between the cutting surface 92 and the pin-out surface of the chip 1 is greater than 45 degrees and less than 135 degrees. For example, the outgoing terminal surface of the chip is perpendicular to the outgoing pin surface of the power module.

Any circuit in fig. 49 to 54 may adopt the power module structure of the present invention, but the present invention is not limited to these circuits, and other suitable circuits may be applied. Where Cin denotes the input capacitance, Co denotes the output capacitance, Vin denotes the input anode of the circuit, GND denotes the input cathode of the circuit, Vo denotes the output anode of the circuit, SW1 denotes the midpoint of the first half-bridge circuit, SW2 denotes the midpoint of the second half-bridge circuit, and V1 denotes the output anode of the half-bridge circuit having a different output voltage than Vo.

Fig. 49 illustrates a Buck circuit. Fig. 50 illustrates a Boost circuit. FIG. 51 illustrates a Buck/Boost circuit. Fig. 52 illustrates a four-switch Buck/Boost circuit, and fig. 53 illustrates an LLC circuit. FIG. 54 illustrates a switched capacitor circuit. Although the power modules are described above with reference to the circuits shown in fig. 49-54, embodiments of the present invention may be used in other circuit topologies. For example, other circuits include, but are not limited to, Cuk circuits or flyback circuits. Similar improvements in performance and effectiveness are possible with reference to similar designs and analyses.

In summary, by using the power module of the present invention, the chip and the passive component are disposed in a flat manner, so that the power module with a smaller height is easier to implement than the stacked structure. Because the chip is basically vertically arranged, the chip is more directly connected with the passive element, and the current impedance and the loss or parasitic inductance can be reduced; and because the chip is basically vertically arranged, the occupied area of the power module is favorably reduced, the structure is more compact, and the power density is higher. The upper surface and the lower surface of the power supply module are better in symmetry, so that heat dissipation paths are more conveniently and symmetrically arranged on the upper surface and the lower surface, or connecting pins are symmetrically arranged on the upper surface and the lower surface, and the like.

The present invention has been described in the embodiments, however, the embodiments are only examples for implementing the present invention and do not limit the scope of the present invention. Rather, it is intended that all such modifications and variations be included within the spirit and scope of this invention.