SUPPLY CIRCUIT FOR POWER MODULE WITH BUILT-IN ISOLATION TRANSFORMER AND ASSOCIATED POWER MODULE

Abstract

Electrical power supply circuit for a power module comprising an electrical transformer, a first substrate having a first side including a heat sink and a second side, a second substrate having a first side including a heat sink and a second side, first metal tracks disposed on the second side of the first substrate, second metal tracks disposed on the second side of the second substrate, electrical connectors disposed between the first and second substrates to electrically connect a first metal track to a second metal track, the primary circuit of the electrical transformer comprising a first part of the first metal tracks and a first part of the second metal tracks, and the secondary circuit of the electrical transformer comprising a second part of the first metal tracks and a second part of the second metal tracks.

Claims

1. An electrical power supply circuit for a power module, the electrical power supply circuit comprising an electrical transformer-including a primary circuit and a secondary circuit, wherein it comprises: a first substrate having a first side including a heat sink and a second side opposite to the first side, a second substrate having a first side including a heat sink and a second side opposite to the first side, first metal tracks disposed on the second side of the first substrate, second metal tracks disposed on the second side of the second substrate, electrical connectors disposed between the second side of the first substrate and the second side of the second substrate to electrically connect a first metal track to a second metal track, the primary circuit of the electrical transformer comprising a first part of the first metal tracks and a first part of the second metal tracks, and the secondary circuit of the electrical transformer comprising a second part of the first metal tracks and a second part of the second metal tracks.

2. The electrical power supply circuit according to claim 1, comprising an electrical isolator made of polymer material in which the electrical elements disposed between the first and second substrates are encapsulated.

3. The electrical power supply circuit according to claim 1, further comprising a magnetic circuit formed by a magnetic core inserted between the first and second metal tracks and surrounded by at least a part of said electrical connectors.

4. The electrical power supply circuit according to claim 3, wherein the magnetic core is produced by an additive manufacturing process such as a powder injection molding process.

5. The electrical power supply circuit according to claim 1, wherein the electrical transformer is devoid of magnetic core.

6. The electrical power supply circuit according to claim 1, wherein the first substrate and the second substrate are manufactured by additive manufacturing.

7. A power module comprising electrical power components, a circuit for controlling the power module, an electrical circuit for supplying the power module according to claim 1, and a first and second module substrates each having a first side including a heat sink and a second side opposite to the first side, the second sides of the first and second substrates being disposed facing each other, and the electrical power supply circuit, the control circuit and the electrical power components being disposed between the first and second substrates, the first substrate of the electrical power supply circuit being formed by a part of the first module substrate and the second substrate of the electrical power supply circuit being formed by a part of the second module substrate.

8. An aircraft comprising at least one power module according to claim 7.

9. The electrical power supply circuit according claim 2, further comprising a magnetic circuit formed by a magnetic core inserted between the first and second metal tracks and surrounded by at least a part of said electrical connectors.

10. The electrical power supply circuit according to claim 2, wherein the electrical transformer is devoid of magnetic core.

11. The electrical power supply circuit according to claim 2, wherein the first substrate and the second substrate are manufactured by additive manufacturing.

12. The electrical power supply circuit according to claim 3, wherein the first substrate and the second substrate are manufactured by additive manufacturing.

13. The electrical power supply circuit according to claim 4, wherein the first substrate and the second substrate are manufactured by additive manufacturing.

14. The electrical power supply circuit according to claim 5, wherein the first substrate and the second substrate are manufactured by additive manufacturing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 is a schematic representation of a power module according to one embodiment of the invention.

[0030] FIG. 2 schematically represents an electrical power supply circuit of the power module of FIG. 1 according to a first embodiment.

[0031] FIG. 3 schematically represents an electrical power supply circuit of the power module of FIG. 1 according to a second embodiment.

DESCRIPTION OF THE EMBODIMENTS

[0032] FIG. 1 schematically represents a power module according to one embodiment of the invention.

[0033] The power module 1 comprises electrical power components 2, such as power transistors or other electronic semiconductor components, a circuit for controlling 3 the power module 1 and an electrical circuit for supplying 4 the power module 1.

[0034] The power module 1 further comprises a first substrate 5 having a first side 50 and a second side 55, as well as a second substrate 6 having a first side 60 and a second side 65. The second side 55 of the first substrate 5 is disposed facing the second side 65 of the second substrate 6. The electrical power components 2, the control circuit 3 and the electrical power supply circuit 4 are disposed between the first substrate 5 and the second substrate 6. More particularly, the electrical power components 2, the control circuit 3 and the electrical power supply circuit 4 are each disposed between second side 55 of the first substrate 5 and the second side 65 of second substrate 6.

[0035] The first side 50 of the first substrate 5 and the first side 60 of the second substrate each include a heat sink 7.

[0036] FIG. 2 schematically represents the electrical power supply circuit 4 of the power module 1 of FIG. 1 according to a first embodiment.

[0037] The electrical power supply circuit 4 comprises an electrical transformer 41 including a primary circuit 42 and a secondary circuit 43, and a magnetic core 44. The power supply circuit 4 further comprises a first substrate 45 formed by a portion of the first substrate 5 of the power module 1, and a second substrate 46 formed by a portion of the second substrate 6 of the power module 1.

[0038] The first substrate 45 of the power supply circuit 4 has a first side 450, coincident with the first side 50 of the first substrate 5 of the power module 1, on which the heat sink 7 associated with the first substrate 5 is mounted.

[0039] The second substrate 46 of the power supply circuit 4 has a first side 460, coincident with the first side 60 of the second substrate 6 of the power module 1, on which the heat sink 7 associated with the second substrate 6 is mounted.

[0040] The first substrate 45 of the power supply circuit 4 has a second side 455 opposite to its first side 450, and the second substrate 46 of the power supply circuit 4 has a second side 465 opposite to its first side 460.

[0041] The electrical power supply circuit 4 further comprises first metal tracks 47 disposed on the second side 455 of the first substrate 45 of the electrical power supply circuit 4, and second metal tracks 48 disposed on the second side 465 of the second substrate 46, as well as electrical connectors 49 disposed between the second side 455 of the first substrate 45 of the electrical power supply circuit 4 and the second side 465 of the second substrate 46 of the electrical power supply circuit 4 to electrically connect a first metal track 47 to a second metal track 48 and thus form the turns of the primary and secondary circuits.

[0042] The primary circuit 42 of the electrical transformer 41 comprises a first part of the first metal tracks 47 and a first part of the second metal tracks 48, these first and second tracks 47 and 48 being connected by corresponding electrical connectors 49 to form the turns of the primary circuit, and the secondary circuit 43 of the electrical transformer 41 comprises a second part of the first metal tracks 47 and a second part of the second metal tracks 48, these first and second tracks 47 and 48 being connected by corresponding electrical connectors 49 to form the turns of the secondary circuit.

[0043] The power module 1 also comprises an electrical isolator made of polymer material, such as elastomer or epoxy, extending between the first substrate 5 and the second substrate 6, and in which the electrical elements disposed between the first and second substrates 5 and 6 are taken that is to say the electrical components 2, the control circuit 3, and the transformer 41.

[0044] FIG. 3 schematically represents the electrical power supply circuit 4 of the power module 1 of FIG. 1 according to a second embodiment.

[0045] The electrical power supply circuit 4 illustrated in FIG. 3 differs from the one illustrated in FIG. 2 in that the electrical transformer 41 is devoid of magnetic core 44, which allows improving the resistance of the transformer to high temperatures that is to say to temperatures above 150° C.