Methods of manufacturing inductor modules and power semiconductor systems having inductor modules

1. A method of manufacturing a power semiconductor system, the method comprising:

providing a power stage module comprising one or more power transistor dies attached to or embedded in a first printed circuit board; and

attaching an inductor module to the power stage module such that the inductor module is electrically connected to an output node of the power stage module, the inductor module comprising a ferrite sheet embedded in a second printed circuit board and windings patterned into the second printed circuit board.

2. The method of claim 1 , wherein attaching the inductor module to the power stage module comprises soldering the inductor module to the power stage module.

3. The method of claim 1 , wherein attaching the inductor module to the power stage module comprises laminating the inductor module onto the power stage module.

4. The method of claim 1 , wherein the second printed circuit board comprises an insulating material in which the ferrite sheet is embedded, and first and second metal sheets laminated onto the insulating material over opposite sides of the ferrite sheet, and wherein the windings are formed by metal traces patterned into the first and the second metal metals, and a plurality of electrically conductive vias which extend between the first and the second metal sheets and connect the metal traces to form one or more coils.

5. The method of claim 4 , wherein each individual one of the plurality of electrically conductive vias is disposed in a different through hole formed in the ferrite sheet.

6. The method of claim 5 , wherein sidewalls of the through holes formed in the ferrite sheet are covered by an electrically insulating material.

7. The method of claim 4 , wherein the plurality of electrically conductive vias is electrically insulated from the ferrite sheet.

8. The method of claim 4 , wherein the ferrite sheet has a plurality of elongated openings, and wherein a first group of the plurality of electrically conductive vias passes through a first one of the elongated openings and a second group of the plurality of electrically conductive vias passes through a second one of the elongated openings to connect the metal traces and form the one or more coils.

9. The method of claim 4 , wherein each individual one of the plurality of electrically conductive vias is filled with metal.

10. The method of claim 4 , wherein the ferrite sheet is patterned into an elongated toroid, and wherein a first group of the plurality of electrically conductive vias extends along a first outer elongated side of the toroid, a second group of the plurality of electrically conductive vias extends along a first inner elongated side of the toroid, a third group of the plurality of electrically conductive vias extends along a second inner elongated side of the toroid and a fourth group of the plurality of electrically conductive vias extends along a second outer elongated side of the toroid to connect the metal traces and form the one or more coils.

11. A method of manufacturing a power semiconductor system, the method comprising:

providing a power stage module comprising one or more power transistor dies attached to or embedded in a printed circuit board; and

attaching an inductor module to the power stage module such that the inductor module is electrically connected to an output node of the power stage module, the inductor module comprising an embedded ferrite sheet and metal wiring on both sides of the module connected together by plated through holes.

12. The method of claim 11 , wherein attaching the inductor module to the power stage module comprises soldering the inductor module to the power stage module.

13. The method of claim 11 , wherein attaching the inductor module to the power stage module comprises laminating the inductor module onto the power stage module.

14. A method of manufacturing inductor modules, the method comprising:

embedding a ferrite sheet in an insulating material, the ferrite sheet having a plurality of elongated openings;

laminating first and second metal sheets onto the insulating material over opposite sides of the ferrite sheet to form a panel;

forming holes through the first and the second metal sheets and the insulating material, the holes being aligned with the elongated openings in the ferrite sheet;

plating the holes with metal to form electrically conductive vias that extend between the first and the second metal sheets;

patterning the first and the second metal sheets to form metal traces which are electrically connected by the vias; and

dividing the panel into separate printed circuit boards, each printed circuit board including an inductor module.

15. The method of claim 14 , wherein a plurality of separate ferrite sheets each with a plurality of elongated openings is embedded in the insulating material.

16. The method of claim 15 , further comprising:

inserting pins of a panel jig into respective alignment holes of the separate ferrite sheets, to align the plurality of separate ferrite sheets on the panel jig prior to embedding the separate ferrite sheets in the insulating material.

17. The method of claim 14 , further comprising:

using preformed alignment holes in the ferrite sheet to align forming the holes through the first and the second metal sheets and the insulating material with the elongated openings in the ferrite sheet.

18. The method of claim 17 , wherein using the preformed alignment holes in the ferrite sheet to align forming the holes formed through the first and the second metal sheets and the insulating material with the elongated openings in the ferrite sheet comprises:

locating the preformed alignment holes;

forming new alignment holes through the first and the second metal sheets, the ferrite sheet and the insulating material based on the location of the preformed alignment holes in the ferrite sheet; and

using the new alignment holes to align forming the holes through the first and the second metal sheets and the insulating material with the elongated openings in the ferrite sheet.