Power supply module and power supply device

• US 10,602,614 B2
• Filed: 09/27/2018
• Issued: 03/24/2020
• Est. Priority Date: 04/21/2016
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: Tange, Takayuki, Higashide, Yasuhiro, Wake, Takeshi, Miyashita, Munetake
• Primary Examiner(s): Mayo, III, William H.
• Assistant Examiner(s): Gonzalez, Hiram E
• Application Number:
  US16/143,509
• Publication Number:
  US 20190037700A1
• Time in Patent Office: 544 Days
• CPC Class Codes: H02M 3/155 using semiconductor devices only
• CPC Class Codes: H02M 3/158 including plural semiconductor devices as final control devices for a single load
• CPC Class Codes: H05K 1/11 Printed elements for providing electric connections to or between printed circuits
• CPC Class Codes: H05K 1/182 associated with components mounted in the printed circuit board, e.g. insert mounted components [IMC]
• CPC Class Codes: H05K 2201/10015 Non-printed capacitor
• CPC Class Codes: H05K 2201/1003 Non-printed inductor
• CPC Class Codes: H05K 2201/10166 Transistor
• CPC Class Codes: H05K 2201/10522 Adjacent components
• CPC Class Codes: H05K 2201/10545 Related components mounted on both sides of the PCB
• CPC Class Codes: H05K 5/065 sealed by encapsulation, e.g. waterproof resin forming an integral casing, injection moulding
• CPC Class Codes: H05K 7/02 Arrangements of circuit components or wiring on supporting structure
• CPC Class Codes: H05K 7/1432 specially adapted for power drive units or power converters
• CPC Class Codes: H05K 7/14322 wherein the control and power circuits of a power converter are arranged within the same casing

Abstract

A power supply module includes first and second outer surfaces that are adjacent to and perpendicular or substantially perpendicular to each other. The power supply module includes a substrate that includes a first surface and a side surface, electronic components mounted at least on the first surface, a first resin material provided on the first surface, and terminal electrodes exposed at least at the first outer surface. The first resin member seals the electronic components mounted on the first surface. In the substrate, the first surface is perpendicular or substantially perpendicular to the first outer surface, which extends at least across the side surface of the substrate and the first resin member. The area of the first outer surface is smaller than the area of the second outer surface.

Claims

1. A power supply module that includes a first outer surface and a second outer surface that is adjacent to the first outer surface and perpendicular or substantially perpendicular to the first outer surface, the power supply module comprising:

a substrate that includes a first surface, a second surface that is opposite to the first surface and perpendicular or substantially perpendicular to the first outer surface, and a side surface;

a plurality of electronic components that are mounted on the first surface and the second surface;

a first resin member that is provided on the first surface and that seals the plurality of electronic components mounted on the first surface;

a second resin member that is provided on the second surface and that seals the plurality of electronic components mounted on the second surface;

a terminal electrode that is exposed at least at the first outer surface; and

an inductor that is mounted on the first surface or the second surface and sealed by the first resin member or the second resin member;

wherein

in the substrate, the first surface is perpendicular or substantially perpendicular to the first outer surface;

the first outer surface extends at least across the side surface of the substrate and the first resin member;

an area of the first outer surface is smaller than an area of the second outer surface;

the first outer surface further includes the second resin member;

at least one of the plurality of electronic components is disposed at positions at which the at least one of the plurality of electronic components overlap the inductor when the first surface or the second surface is viewed in plan view;

the plurality of electronic components include an input capacitor that is connected to an input portion, an output capacitor that is connected to an output portion, and a switching element that is connected between the inductor and the input capacitor or between the inductor and the output capacitor and that switches on and off a current that flows through the inductor;

the input capacitor and the output capacitor are mounted on one of the first surface and the second surface; and

the switching element is mounted on another one of the first surface and the second surface different from the one of the first surface and the second surface that the input capacitor and the output capacitor are mounted on.

2. The power supply module according to claim 1, wherein the switching element is disposed at a position at which at least a portion of the switching element overlaps at least one of the input capacitor and the output capacitor when the first surface or the second surface is viewed in plan view.

3. The power supply module according to claim 1, further comprising:

a conductor that is provided in or on the substrate;

wherein

the switching element is disposed at a position at which at least a portion of the switching element overlaps the conductor when the first surface or the second surface is viewed in plan view.

4. The power supply module according to claim 1, wherein

a plurality of the terminal electrodes are provided;

and

each of the plurality of terminal electrodes is exposed to at least the first outer surface.

5. The power supply module according to claim 1, wherein

a plurality of the terminal electrodes are provided;

and

the plurality of terminal electrodes are disposed in a first direction along a ridge of the first outer surface and the second outer surface.

6. A power supply device comprising:

a mounting substrate; and

a plurality of power supply modules each of which includes a first outer surface and a second outer surface that is adjacent to the first outer surface and perpendicular or substantially perpendicular to the first outer surface;

wherein

each of the plurality of power supply modules includes;

a substrate that includes a first surface and a side surface;

a plurality of electronic components that are mounted at least on the first surface;

a first resin member that is provided on the first surface and that seals the plurality of electronic components mounted on the first surface; and

a terminal electrode that is exposed at least at the first outer surface;

in the substrate, the first surface is perpendicular or substantially perpendicular to the first outer surface;

the first outer surface extends at least across the side surface of the substrate and the first resin member;

an area of the first outer surface is smaller than an area of the second outer surface; and

the plurality of power supply modules are disposed in a second direction that is perpendicular or substantially perpendicular to a first direction along a ridge of the first outer surface and the second outer surface and are electrically connected in parallel to each other.

7. The power supply device according to claim 6, wherein the plurality of power supply modules are mounted on the mounting substrate with solder.

8. The power supply device according to claim 6, wherein

the substrate further includes a second surface that is opposite to the first surface and perpendicular or substantially perpendicular to the first outer surface;

at least one of the plurality of electronic components is mounted on the second surface;

each of the plurality of power supply modules further includes a second resin member that is provided on the second surface and that seals the at least one of the plurality of electronic components mounted on the second surface; and

the first outer surface includes the second resin member.

9. The power supply device according to claim 8, further comprising:

an inductor that is mounted on the first surface or the second surface and sealed by the first resin member or the second resin member;

wherein

at least one of the plurality of electronic components is disposed at positions at which the at least one of the plurality of electronic components overlaps the inductor when the first surface or the second surface is viewed in plan view.

10. The power supply device according to claim 9, wherein

the plurality of electronic components include an input capacitor that is connected to an input portion, an output capacitor that is connected to an output portion, and a switching element that is connected between the inductor and the input capacitor or between the inductor and the output capacitor and that switches on and off a current that flows through the inductor;

the input capacitor and the output capacitor are mounted on one of the first surface and the second surface; and

the switching element is mounted on another one of the first surface and the second surface different from the one of the first surface and the second surface that the input capacitor and the output capacitor are mounted on.

11. The power supply device according to claim 10, wherein the switching element is disposed at a position at which at least a portion of the switching element overlaps at least one of the input capacitor and the output capacitor when the first surface or the second surface is viewed in plan view.

12. The power supply device according to claim 10, further comprising:

a conductor that is provided in or on the substrate;

wherein

the switching element is disposed at a position at which at least a portion of the switching element overlaps the conductor when the first surface or the second surface is viewed in plan view.

13. The power supply device according to claim 9, wherein

the plurality of electronic components includes an input capacitor that is connected to an input portion, an output capacitor that is connected to an output portion, and at least one switching element that is connected between the inductor and the input capacitor and between the inductor and the output capacitor and that switches on and off a current that flows through the inductor;

the input capacitor and the output capacitor are mounted on one of the first surface and the second surface; and

the at least one switching element is mounted on another one of the first surface and the second surface, different from the one of the first surface and the second surface.

14. The power supply device according to claim 6, wherein

a plurality of the terminal electrodes are provided;

and

each of the plurality of terminal electrodes is exposed to at least the first outer surface.

15. The power supply device according to claim 6, wherein

a plurality of the terminal electrodes are provided;

and

the plurality of terminal electrodes are disposed in a first direction along a ridge of the first outer surface and the second outer surface.

16. A power supply module that includes a first outer surface and a plurality of outer surfaces that are adjacent to the first outer surface and perpendicular or substantially perpendicular to the first outer surface, the power supply module comprising:

a substrate that includes a first surface, a second surface that is opposite to the first surface, and a side surface;

a plurality of electronic components that are mounted on the first surface and the second surface;

a terminal electrode that is provided on the first surface; and

a first resin member and a second resin member that are respectively provided on the first surface and the second surface and that seal the electronic components mounted on the first surface and the second surface;

in the substrate, the first surface and the second surface are perpendicular or substantially perpendicular to the first outer surface;

the first outer surface extends at least across the first resin member and the second resin member;

the terminal electrode is exposed at least at the first outer surface; and

an area of the first outer surface is smaller than an area of any of the plurality of outer surfaces.

17. The power supply module according to claim 16, further comprising:

an inductor that is mounted on the second surface;

wherein

the terminal electrode is provided only on the first surface.

18. The power supply module according to claim 17, wherein

the plurality of electronic components includes an input capacitor that is connected to an input portion, an output capacitor that is connected to an output portion, and at least one switching element that is connected between the inductor and the input capacitor and between the inductor and the output capacitor and that switches on and off a current that flows through the inductor;

and

the input capacitor and the output capacitor are mounted on one of the first surface and the second surface.

19. The power supply module according to claim 18, wherein the at least one switching element is disposed at a position at which at least a portion of the at least one switching element overlaps at least one of the input capacitor and the output capacitor when the first surface or the second surface is viewed in plan view.

20. The power supply module according to claim 16, wherein

a plurality of the terminal electrodes are provided;

and

each of the plurality of terminal electrodes is exposed to at least the first outer surface.