Switch-mode converter module
A method for manufacturing a switch-mode converter includes forming a plurality of windings by coiling one or more conductors. Each of the windings is secured to one of a plurality of module bases arranged in a module array. At least one side of the array is encapsulated in a magnetic mold compound.
1. A method for manufacturing a switch-mode converter, comprising:
attaching a power supply switching component to a module substrate;
coiling a conductor to form a winding;
securing the winding to the module substrate;
inserting a core of magnetic material into the winding; and
covering the power supply switching component, the winding, and the core in a magnetic mold compound.
2. The method of claim 1 , further comprising attaching the winding to a winding lead frame prior to the securing.
3. The method of claim 2 , wherein the securing comprises attaching the winding lead frame to the module substrate.
4. The method of claim 1 , wherein the power supply switching component is disposed between the module substrate and the winding.
5. The method of 1 , wherein the conductor is round or rectangular.
6. The method of 1 , wherein the covering comprises encasing all components attached to one side of the module substrate in the magnetic mold compound.
7. The method of claim 1 , wherein the securing comprising coupling the winding to the power supply switching component.
8. A switch-mode power supply module, comprising:
a substrate;
a winding attached to the substrate;
a power supply switching component attached to the substrate, wherein the power supply switching component is configured to drive the winding;
a magnetic core disposed in the winding; and
magnetic mold compound encasing the winding, the magnetic core, and the power supply switching component.
9. The switch-mode power supply module of claim 8 , further comprising a winding lead frame; wherein the winding is attached to the winding lead frame, and the winding lead frame is affixed to the substrate.
10. The switch-mode power supply module of claim 8 , wherein a diameter of a first end of the magnetic core is greater than a diameter of a second end of the magnetic core.