Power module with integrated gate driver and functional components within a single power module housing
An apparatus comprises a power module housing. The power module housing includes a conductive substrate and a circuit board positioned overlying the conductive substrate. A gate driver is mounted to the circuit board. A power device is mounted to the conductive substrate and is controlled by the gate driver. The power module housing includes an insulation material electrically insulating the conductive substrate from the circuit board. A monitoring component is mounted to at least the conductive substrate and is operatively coupled to the gate driver and the power device.
1. An apparatus, comprising:
a power module housing including:
a conductive substrate;
a circuit board positioned overlying the conductive substrate, wherein the circuit board operates at a first voltage level and the conductive substrate operates at a second voltage level higher than the first voltage level;
an insulation material electrically insulating the conductive substrate from the circuit board;
a gate driver mounted to the circuit board;
at least one power device mounted to the conductive substrate and controlled by the gate driver; and
a monitoring component mounted to at least the conductive substrate and operatively coupled to the gate driver and the power device.
2. The apparatus of claim 1 , wherein the monitoring component is configured to turn off the at least one power device based on a parameter of the at least one power device.
3. The apparatus of claim 1 , wherein the monitoring component is configured to provide a signal indicative of a parameter of the at least one power device to the gate driver and wherein the gate driver is configured to turn off the at least one power device.
4. The apparatus of claim 1 , wherein the monitoring component is configured to provide a signal indicative of a parameter of the at least one power device to the gate driver and wherein the gate driver is configured to provide the signal to an external controller.
5. The apparatus of claim 1 , wherein the conductive substrate comprises one of a direct copper bonded (DCB) board and an insulated metal substrate (IMS) board.
6. The apparatus of claim 1 , wherein the insulation material comprises a potting gel.
7. The apparatus of claim 1 , comprising:
a conductive connector electrically coupling the gate driver to the at least one power device, wherein the insulation material is formed around the conductive connector and electrically insulates the gate driver from the power device.
8. The apparatus of claim 1 , comprising:
a conductive connector electrically coupling the conductive substrate to the circuit board, wherein the insulation material is formed around the conductive connector.
9. The apparatus of claim 1 , comprising:
a conductive connector electrically coupling at least part of the monitoring component to the circuit board, wherein the insulation material is formed around the conductive connector and electrically insulates the circuit board from the monitoring component.
10. The apparatus of claim 1 , comprising:
a circuit board connector coupled to the circuit board and providing connectivity outside the power module housing.
11. The apparatus of claim 1 , wherein the monitoring component comprises an overcurrent protection device.
12. The apparatus of claim 1 , comprising an internal power supply mounted on the conductive substrate and providing power to at least the gate driver.
13. An apparatus, comprising:
a power module housing including:
a conductive substrate;
a circuit board positioned overlying the conductive substrate;
an insulation material electrically insulating the conductive substrate from the circuit board;
a gate driver mounted to the circuit board;
at least one power device mounted to the conductive substrate and controlled by the gate driver; and
a monitoring component mounted to at least the conductive substrate and operatively coupled to the gate driver and the power device, wherein the monitoring component is configured to provide a signal indicative of a parameter of the at least one power device to the gate driver and wherein the gate driver is configured to provide the signal to an external controller.
14. The apparatus of claim 13 , wherein the circuit board operates at a first voltage level and the conductive substrate operates at a second voltage level higher than the first voltage level.
15. An apparatus, comprising:
a power module housing including:
a conductive substrate;
a circuit board positioned overlying the conductive substrate;
an insulation material electrically insulating the conductive substrate from the circuit board;
a gate driver mounted to the circuit board;
at least one power device mounted to the conductive substrate and controlled by the gate driver;
a monitoring component mounted to at least the conductive substrate and operatively coupled to the gate driver and the power device; and
a conductive connector electrically coupling the conductive substrate to the circuit board, wherein the insulation material is formed around the conductive connector.
16. The apparatus of claim 15 , wherein the monitoring component comprises a current measurement device or a voltage measurement device.
17. An apparatus, comprising:
a power module housing including:
a conductive substrate;
a circuit board positioned overlying the conductive substrate;
an insulation material electrically insulating the conductive substrate from the circuit board;
a gate driver mounted to the circuit board;
at least one power device mounted to the conductive substrate and controlled by the gate driver;
a monitoring component mounted to at least the conductive substrate and operatively coupled to the gate driver and the power device; and
a conductive connector electrically coupling at least part of the monitoring component to the circuit board, wherein the insulation material is formed around the conductive connector and electrically insulates the circuit board from the monitoring component.
18. The apparatus of claim 17 , wherein the monitoring component comprises at least one of a current measurement device, a voltage measurement device, a temperature protection device, an overcurrent protection device, or a rectifier.
19. An apparatus, comprising:
a power module housing including:
a conductive substrate;
a circuit board positioned overlying the conductive substrate;
an insulation material electrically insulating the conductive substrate from the circuit board;
a gate driver mounted to the circuit board;
at least one power device mounted to the conductive substrate and controlled by the gate driver; and
a monitoring component mounted to at least the conductive substrate and operatively coupled to the gate driver and the power device; and
an internal power supply mounted on the conductive substrate and providing power to at least the gate driver.
20. The apparatus of claim 19 , comprising a plurality of power devices mounted on the conductive substrate, the plurality of power devices implementing one of a half bridge, a full bridge, a three-phase inverter, a rectifier, or a converter from AC to DC or AC or from DC to DC or AC.