Trans-inductor voltage regulator (TLVR) inductor module and power electronics assembly including the TLVR inductor module

1 . A trans-inductor voltage regulator (TLVR) inductor module, comprising:

a magnetic core;

a first winding embedded in the magnetic core;

a second winding embedded in the magnetic core and inductively coupled to the first winding;

a third winding embedded in the magnetic core;

a fourth winding embedded in the magnetic core and inductively coupled to the third winding; and

a first integrated metallic connector that connects the second winding and the fourth winding in a series loop,

wherein a first end and a second end of the first winding and a first end and a second end of the third winding are exposed at a first side of the TLVR inductor module,

wherein the first integrated metallic connector interconnects a first end of the second winding and a first end of the fourth winding at the first side of the TLVR inductor module,

wherein the first winding covers the second winding,

wherein the third winding covers the fourth winding, and

wherein the first winding and the third winding are exposed at a second side of the TLVR inductor module opposite the first side.

2 . The TLVR inductor module of claim 1 ,

wherein a second end of the second winding and a second end of the fourth winding are exposed at the first side of the TLVR inductor module.

3 . The TLVR inductor module of claim 1 ,

wherein a single continuous metallic body forms the second winding, the fourth winding, and the first integrated metallic connector.

4 . The TLVR inductor module of claim 1 ,

wherein the first integrated metallic connector is separate from the second winding and the fourth winding, and

wherein the first integrated metallic connector is attached to the first end of the second winding and the first end of the fourth winding.

5 . The TLVR inductor module of claim 1 , further comprising:

a fifth winding embedded in the magnetic core;

a sixth winding embedded in the magnetic core and inductively coupled to the fifth winding; and

a second integrated metallic connector that connects the sixth winding in the series loop.

6 . The TLVR inductor module of claim 5 ,

wherein a first end and a second end of the fifth winding are exposed at the first side of the TLVR inductor module,

wherein the second integrated metallic connector interconnects a second end of the fourth winding and a first end of the sixth winding at the first side of the TLVR inductor module.

7 . The TLVR inductor module of claim 6 ,

wherein a second end of the second winding and a second end of the sixth winding are exposed at the first side of the TLVR inductor module.

8 . A power electronics assembly, comprising:

a power stage module comprising a circuit board and a plurality of power semiconductor dies attached to or embedded in the circuit board and electrically interconnected to form part of a power converter circuit; and

a trans-inductor voltage regulator (TLVR) inductor module directly mounted to the circuit board of the power stage module without any intervening circuit board,

wherein the TLVR inductor module comprises:

a magnetic core;

a first winding embedded in the magnetic core;

a second winding embedded in the magnetic core and inductively coupled to the first winding;

a third winding embedded in the magnetic core;

a fourth winding embedded in the magnetic core and inductively coupled to the third winding; and

a first integrated metallic connector that connects the second winding and the fourth winding in a series loop,

wherein the first winding and the third winding form part of the power converter circuit,

wherein a first end and a second end of the first winding and a first end and a second end of the third winding are exposed at a first side of the TLVR inductor module and attached to the circuit board of the power stage module, and

wherein the first integrated metallic connector interconnects a first end of the second winding and a first end of the fourth winding at the first side of the TLVR inductor module.

9 . The power electronics assembly of claim 8 , further comprising:

an inductor outside the TLVR inductor module and part of the series loop that includes the second winding and the fourth winding of the TLVR inductor module.

10 . The power electronics assembly of claim 8 ,

wherein a second end of the second winding and a second end of the fourth winding are exposed at the first side of the TLVR inductor module and attached to the circuit board of the power stage module.

11 . The power electronics assembly of claim 10 , further comprising:

an inductor attached to the circuit board of the power stage module and included in the series loop between the second end of the second winding and the second end of the fourth winding.

12 . The power electronics assembly of claim 10 ,

wherein the second end of the second winding and the second end of the fourth winding are grounded.

13 . The power electronics assembly of claim 8 ,

wherein the first winding and the third winding are exposed at a side of the TLVR inductor module that faces away from the power stage module.

14 . The power electronics assembly of claim 13 , further comprising:

a heat exchanger mounted to the side of the TLVR inductor module that faces away from the power stage module,

wherein the heat exchanger is thermally coupled to the exposed part of the first winding and the third winding at the side of the TLVR inductor module that faces away from the power stage module.

15 . The power electronics assembly of claim 8 ,

wherein the power semiconductor dies of the power stage module are attached to a side of the circuit board to which the TLVR inductor module is directly mounted, and

wherein the power semiconductor dies are interposed between the TLVR inductor module and the circuit board.

16 . A trans-inductor voltage regulator (TLVR) inductor module, comprising:

a magnetic core;

a first winding embedded in the magnetic core;

a second winding embedded in the magnetic core and inductively coupled to the first winding;

a third winding embedded in the magnetic core;

a fourth winding embedded in the magnetic core and inductively coupled to the third winding; and

a first integrated metallic connector that connects the second winding and the fourth winding in a series loop,

wherein a first end and a second end of the first winding and a first end and a second end of the third winding are exposed at a first side of the TLVR inductor module,

wherein the first integrated metallic connector interconnects a first end of the second winding and a first end of the fourth winding at the first side of the TLVR inductor module,

wherein the second winding is arranged side-by-side the first winding,

wherein the fourth winding is arranged side-by-side the third winding, and

wherein the first winding and the third winding are exposed at a second side of the TLVR inductor module opposite the first side.

17 . The TLVR inductor module of claim 16 ,

wherein the second winding and the fourth winding are exposed at the second side of the TLVR inductor module.

18 . A trans-inductor voltage regulator (TLVR) inductor module, comprising:

a magnetic core;

a first winding embedded in the magnetic core;

a second winding embedded in the magnetic core and inductively coupled to the first winding;

a third winding embedded in the magnetic core;

a fourth winding embedded in the magnetic core and inductively coupled to the third winding;

a first integrated metallic connector that connects the second winding and the fourth winding in a series loop;

a fifth winding embedded in the magnetic core;

a sixth winding embedded in the magnetic core and inductively coupled to the fifth winding; and

a second integrated metallic connector that connects the sixth winding in the series loop,

wherein a first end and a second end of the first winding, a first end and a second end of the third winding, and a first end and a second end of the fifth winding are exposed at a first side of the TLVR inductor module,

wherein the first integrated metallic connector interconnects a first end of the second winding and a first end of the fourth winding at the first side of the TLVR inductor module, and

wherein the second integrated metallic connector interconnects a second end of the fourth winding and a first end of the sixth winding at the first side of the TLVR inductor module.

19 . The TLVR inductor module of claim 18 ,

wherein a second end of the second winding and a second end of the sixth winding are exposed at the first side of the TLVR inductor module.

20 . A power electronics assembly, comprising:

a power stage module comprising a circuit board and a plurality of power semiconductor dies attached to or embedded in the circuit board and electrically interconnected to form part of a power converter circuit; and

a trans-inductor voltage regulator (TLVR) inductor module directly mounted to the circuit board of the power stage module without any intervening circuit board,

wherein the TLVR inductor module comprises:

a magnetic core;

a first winding embedded in the magnetic core;

a second winding embedded in the magnetic core and inductively coupled to the first winding;

a third winding embedded in the magnetic core;

a fourth winding embedded in the magnetic core and inductively coupled to the third winding;

a first integrated metallic connector that connects the second winding and the fourth winding in a series loop; and

a heat exchanger mounted to a side of the TLVR inductor module that faces away from the power stage module,

wherein the first winding and the third winding form part of the power converter circuit,

wherein the first winding and the third winding are exposed at the side of the TLVR inductor module that faces away from the power stage module,

wherein the heat exchanger is thermally coupled to the exposed part of the first winding and the third winding at the side of the TLVR inductor module that faces away from the power stage module.

21 . A power electronics assembly, comprising:

a power stage module comprising a circuit board and a plurality of power semiconductor dies attached to or embedded in the circuit board and electrically interconnected to form part of a power converter circuit; and

a trans-inductor voltage regulator (TLVR) inductor module directly mounted to the circuit board of the power stage module without any intervening circuit board,

wherein the TLVR inductor module comprises:

a magnetic core;

a first winding embedded in the magnetic core;

a second winding embedded in the magnetic core and inductively coupled to the first winding;

a third winding embedded in the magnetic core;

a fourth winding embedded in the magnetic core and inductively coupled to the third winding; and

a first integrated metallic connector that connects the second winding and the fourth winding in a series loop,

wherein the first winding and the third winding form part of the power converter circuit,

wherein the power semiconductor dies of the power stage module are attached to a side of the circuit board to which the TLVR inductor module is directly mounted, and

wherein the power semiconductor dies are interposed between the TLVR inductor module and the circuit board.