Power supply module

A power-supply module includes at least one power-supply component, an inductor and a package. The inductor is disposed over the at least one power-supply components, and the at least a power-supply component and the inductor are disposed within the package. Besides, the power-supply module further comprises a printed circuit board, and the at least one power-supply component and the inductor are mounted to the printed circuit board. Moreover, the inductor comprises a plurality of leads that support the inductor over the at least one power-supply component.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates to a package structure. More particularly, the present invention relates to an electronic package structure.

II. Description of the Prior Art

Electronic package structures are formed by complicated package processes. Different electronic package structures have different electrical performances and capacities of heat dissipation, and therefore a designer may select an electronic package structure with a desired electrical performance and capacity of heat dissipation according to a design requirement.

FIG. 1is a schematic diagram of a conventional electronic package structure. Referring toFIG. 1, the conventional electronic package structure100includes a printed circuit board (PCB)110and a plurality of electronic elements120. The electronic elements120are disposed on a surface112of the PCB110and electrically connected to the PCB110. The PCB110has a plurality of pins116extending out from another surface114of the PCB110to be electrically connected to an electronic device, for example, a motherboard (not shown).

FIG. 2is a schematic diagram of another conventional electronic package structure. Referring toFIG. 2, the conventional electronic package structure200includes a circuit substrate210and a plurality of electronic elements220. The electronic elements220are disposed on a surface212of the circuit substrate210, and electrically connected to the circuit substrate210via a wire bonding technology, a flip-chip bonding technology or a surface mount technology. Moreover, the conventional electronic package structure200may be electrically connected to an electronic device, for example, a motherboard (not shown), via a solder paste or a plurality of solder balls (not shown).

It should be noted that the electronic elements120of the conventional electronic package structure100are all disposed on the surface112of the PCB110, and the electronic elements220of the conventional electronic package structure200are all disposed on the surface212of the circuit substrate210. Therefore, in the conventional electronic package structures100and200, spatial utilization of the PCB110and the circuit substrate210is relatively low, and sizes of the conventional electronic package structures100and200are relatively great.

SUMMARY OF THE INVENTION

In accordance with the present invention, an electronic package structure can achieve a relatively high utilization of an internal space thereof, so that a size of the electronic package structure can be reduced.

In one embodiment of the present invention, an electronic package structure includes at least a first electronic element, a second electronic element and a first lead frame. The second electronic element includes a body having a cavity. The first electronic element is disposed in the cavity. The lead frame has a plurality of leads. Each of the leads has a first end and a second end, and the first end of at least one of the leads extends to the cavity to electrically connect the first electronic element.

In one embodiment of the present invention, an electronic package structure includes at least one first electronic element, a second electronic element and a lead frame. The second electronic element includes a body having a first surface. The lead frame has a plurality of leads. Each of the leads has a first end and a second end. The first ends are disposed on the first surface, and the first electronic element is disposed on the first surface and electrically connected to at least one of the leads.

In one embodiment, an electronic package structure includes a circuit substrate, at least one first electronic element and a second electronic element. The circuit substrate has a first surface. The first electronic element is disposed on the first surface of the circuit substrate and electrically connected to the circuit substrate. The second electronic element is disposed above the first surface of the circuit substrate and includes a body and a plurality of leads. Each of the leads has a first end and second end, and the second end of each of the leads extends out from the body to electrically connect the circuit substrate. The first electronic element is located among the body of the second electronic element, the first surface of the circuit substrate and the leads.

In the above embodiments of the present invention, since the first electronic element can be disposed in the cavity of the second electronic element or on the second electronic element, or the second electronic element can be stacked on the first electronic element, compared to the conventional electronic package structures, utilization of an internal space of the electronic package structure is relatively high.

The detailed technology and above preferred embodiments implemented for the present invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention.

DETAILED DESCRIPTION OF THE INVENTION

The detailed explanation of the present invention is described as following. The described preferred embodiments are presented for purposes of illustrations and descriptions, and they are not intended to limit the scope of the present invention.

First Embodiment

FIG. 3Ais a schematic diagram of an electronic package structure according to a first embodiment of the present invention. Referring toFIG. 3A, the electronic package structure300includes at least one first electronic element310(two first electronic elements are illustrated inFIG. 3A), a second electronic element320and a first lead frame330. The electronic package structure300is generally applied to a power-supply module, a voltage regulator module, a network adapter, a graphics processing unit, a DC/DC converter or a point-of-load (POL) converter. Each of the first electronic elements310can be a power-supply component such as a logical control element (a controller), a driving element, a metal-oxide-semiconductor field effect transistor (MOSFET), an insulated gate bipolar transistor (IGBT), a diode or a passive element. The passive element can be a capacitor, an inductor with lesser inductance, or a resistor.

The second electronic element320includes a body322having a cavity322a. The first electronic elements310are disposed in the cavity322a. In the embodiment, the body322of the second electronic element320has a first surface322b, a second surface322copposite to the first surface322band a side surface322d. The cavity322asinks in a direction from the second surface322ctowards the first surface322b. The side surface322dconnects the first surface322band the second surface322c. Besides, the second electronic element320can be an energy-storage element used for storing electric energy. In detail, the second electronic element320further includes a coil324and a plurality of first external electrodes326. The coil324is disposed within the body322. The first external electrodes326are respectively connected to two opposite ends of the coil324, and extend outside the body322to locate on the first surface322band the side surface322d. The body322comprising a magnetic body encloses the coil324. The second electronic element320can be an inductive element, such as an inductor, with a greater inductance and a greater size than the first electronic elements310.

The first lead frame330has a plurality of leads332. Each of the leads332has a first end332aand a second end332b, and the first end332aof each of the leads332can be embedded in the body322and extends to the cavity322afor electrically connecting to the first electronic elements310. The second end332bof each of the leads332is disposed on the first surface322bof the body322to form a second external electrode332c, and a part of each of the leads332connecting the first end332aand the second end332bis disposed on the side surface322dof the body322.

In the present embodiment, the electronic package structure300further includes a platform, such as a circuit substrate340, and an insulating encapsulant350. The circuit substrate340is disposed in the cavity322aof the body322. The first electronic elements310can be disposed on the circuit substrate340and electrically connected to the circuit substrate340. The circuit substrate340is electrically connected to the first end332aof each of the leads332extending to the cavity322a. The first electronic elements310may be electrically connected to the circuit substrate340via a wire bonding technology, a flip-chip bonding technology or a surface mount technology. The circuit substrate340has a first circuit layer342, a second circuit layer344, a dielectric layer346disposed between the first circuit layer342and the second circuit layer344, and at least a conductive channel348. The first electronic elements310are disposed on the first circuit layer342, and the conductive channel348penetrates the dielectric layer346for electrically connecting the first circuit layer342and the second circuit layer344. It should be noted that the circuit board340of the electronic package structure300may be omitted according to a design requirement of a designer, though it is not illustrated.

Moreover, the insulating encapsulant350is disposed in the cavity322aand encapsulates the first electronic elements310and the circuit substrate340for protecting the first electronic elements310and the circuit substrate340, and enhancing a whole mechanical strength of the electronic package structure300.

Since the first electronic elements310and the circuit substrate340are disposed in the cavity322aof the second electronic element320, compared to a conventional electronic package structures ofFIG. 1andFIG. 2, utilization of an internal space of the electronic package structure300is relatively high, and the first electronic elements310and the circuit substrate340can be protected by the cavity322a. Besides, since the insulating encapsulant350is disposed in the cavity322a, material of the insulating encapsulant350can be directly filled into the cavity322awithout aiding of extra mold during formation of the insulating encapsulant350.

FIG. 3Bis a schematic diagram of another electronic package structure according to the first embodiment of the present invention. Referring toFIG. 3AandFIG. 3B, a difference between the electronic package structure300′ and the electronic package structure300is that a part of each lead332′ connecting a first end332a′ and a second end332b′ penetrates a body322′. Besides, the insulating encapsulant350of the electronic package structure300is different from a magnetic encapsulant350′ of the electronic package structure300′. The magnetic encapsulant350′ is disposed in a cavity322a′ of the body322′. Therefore, if a second electronic element320′ is an inductive element, an inductive characteristic of the second electronic element320′ influenced by the cavity322′ then can be compensated by the magnetic encapsulant350′. It should be noted that a part of each of the leads332connecting the first end332aand the second end332bmay also penetrate the body322according to a design requirement, though it is not illustrated.

FIG. 3Cis a schematic diagram of another electronic package structure according to the first embodiment of the present invention. Referring toFIG. 3AandFIG. 3C, a difference between the electronic package structure300″ and the electronic package structure300is that a cavity322a″ of a body322″ sinks in a direction from a first surface322b″ towards a second surface322c″. It should be noted that an insulating encapsulant350″ can be substituted by a magnetic encapsulant according to a design requirement, and a part of each lead332″ connecting a first end332a″ and a second end332b″ may also penetrate the body322″ according to a design requirement, though it is not illustrated.

FIG. 3Dis a schematic diagram of still another electronic package structure according to the first embodiment of the present invention. Referring toFIG. 3AandFIG. 3D, a second lead frame360is applied in the electronic package structure300′″ for substituting the circuit substrate340of the electronic package structure300according to a design requirement. A plurality of first electronic elements310′″ are disposed on the second lead frame360and electrically connected to the second lead frame360. The second lead frame360is electrically connected to a first end332a′″ of each lead332′″ of a first lead frame330′″ that extends to a cavity322a′″.

Second Embodiment

FIG. 4Ais a schematic diagram of an electronic package structure according to a second embodiment of the present invention. Referring toFIG. 4AandFIG. 3A, a difference between the electronic package structure400of the second embodiment and the electronic package structure300of the first embodiment is that a body422of a second electronic element420does not have the cavity322a. In detail, a first end432aof each lead432of a lead frame430is disposed on a first surface422aof a body422, and a plurality of first electronic elements410are disposed on the first surface422aand electrically connected to the leads432. Moreover, a second end432bof each of the leads432is disposed on a second surface422bof the body422opposite to the first surface422a, and a part of each of the leads432connecting the first end432aand the second end432bis disposed on a side surface422cof the body422.

Furthermore, a platform, such as a circuit substrate440, is disposed on the first surface422aand electrically connected to the leads432, and the first electronic elements410are disposed on the circuit substrate440and electrically connected to the circuit substrate440. It should be noted that the circuit substrate440of the electronic package structure400may be omitted according to a design requirement of the designer, or the circuit substrate440may be substituted by a lead frame, though it is not illustrated.

FIG. 4Bis a schematic diagram of another electronic package structure according to the second embodiment of the present invention. Referring toFIG. 4AandFIG. 4B, a difference between the electronic package structure400′ and the electronic package structure400is that a part of each lead432′ connecting a first end432a′ and a second end432b′ penetrates a body422′.

Third Embodiment

FIG. 5Ais a schematic diagram of an electronic package structure according to a third embodiment of the present invention. Referring toFIG. 5A, in the electronic package structure500of the present embodiment, a plurality of first electronic elements510are disposed on a first surface532of a platform, such as a printed circuit board or a circuit substrate530as shown inFIG. 5A, and electrically connected to the circuit substrate530. A second electronic element520is disposed above the first surface532of the circuit substrate530. The first electronic elements510are located between a body522of the second electronic element520and the first surface532of the circuit substrate530, and the first electronic elements510are located between leads524of the second electronic element520. In other words, in the present embodiment, the second electronic element520covers the first electronic elements510. Besides, an insulating encapsulant540is disposed between the second electronic element520and the circuit substrate530and encapsulating the first electronic elements510for protecting the first electronic elements510and enhancing a whole mechanical strength of the electronic package structure500. Alternatively, the insulating encapsulant540can also be disposed to encapsulate at least part of the circuit substrate530, the first electronic elements510and the second electronic element520, or completely encapsulate all of them. Moreover, the circuit substrate530may further include at least a conductive channel539, and each of the conductive channels539penetrates a dielectric layer538for electrically connecting a first circuit layer534and a second circuit layer536. At least one of the conductive channels539(for example, the two conductive channels539located at a left side ofFIG. 5A) is located below at least one of the first electronic elements510(for example, the first electronic element510located at the left side ofFIG. 5A), so that heat generated by the first electronic element510located at the left side may be quickly transmitted to where is outside the electronic package structure500via the two conductive channels539located at the left side. A second end524bof each of the leads524of the second electronic element520extends out from the body522to electrically connect the circuit substrate530. The second electronic element520may be an inductive element including a coil526. The body522which is a magnetic wrap wraps the coil526, and a first end524aof each of the leads524is connected to one of two opposite ends of the coil526.

Still referring toFIG. 5A, an embodiment of a method for manufacturing the electronic package structure500is described.

First, the plurality of first electronic elements510and any other components of the electronic package structure500are mounted to the circuit substrate530, the bottom pads of the components are soldered to corresponding pads of the circuit substrate.

Next, the upper pads (if any are present) of the components are wire bonded to corresponding pads of the circuit substrate530.

Then, the leads524of the second electronic element520are shaped, and the second electronic element520is mounted to the circuit substrate530, e.g., by soldering the leads to corresponding pads of the circuit substrate.

Next, the insulating encapsulant540is formed between the second electronic element520and the circuit substrate530and encapsulating the first electronic elements510by conventional methods. Alternatively, the insulating encapsulant540can also be formed to encapsulate at least part of the circuit substrate530, the first electronic elements510and the second electronic element520, or completely encapsulate all of them by conventional methods, such as injection molding of epoxy resin.

Then, the leads (not shown inFIG. 5A) of the electronic package structure500are shaped, and the electronic package structure can be tested and shipped to customers.

It should be noted that the electronic package structure500further includes an electromagnetic-interference-shielding element (EMI-shielding element)550covering the first electronic elements510. In the present embodiment, the EMI-shielding element550is disposed on the body522of the second electronic element520, and is located between the body522of the second electronic element520and the circuit substrate530. Therefore, during operation of the electronic package structure500, it may be reduced by means of the EMI-shielding element550that electrical signals transmitted in the circuit substrate530is interfered by a magnetic force generated by the second electronic element520which functions as an inductive element.

FIG. 5Bis a schematic diagram of another electronic package structure according to the third embodiment of the present invention. Referring toFIG. 5AandFIG. 5B, a difference between the electronic package structure500′ and the electronic package structure500is that an EMI-shielding element550′ of the electronic package structure500′ is disposed in a cavity522′ of a second electronic element520′.

FIG. 6is a side view of an embodiment of a second electronic element such as an inductor620, which can be used in the aforementioned electronic package structure. Each of the leads624is extensions of the inductor winding and has two bends6240and6242. For example, the angles of the bends6240and6242can be between approximately 30 and 90 degrees. Furthermore, although not shown, the bottoms of the leads624can also be bent at an approximately 90 degree angle to increase the mounting stability of the inductor620. Moreover, although only two leads624are shown, the inductor620can have more than two leads (e.g., four leads), to increase the mounting stability of the inductor, to reduce the lead resistance, etc.

FIG. 7is a schematic diagram of an embodiment of a system70, which can incorporate one or more embodiments of the aforementioned electronic package structure; for example, the electronic package structure can be a power-supply module700as shown inFIG. 7, where the module700includes a buck converter.

In addition to the module700, the system70includes an apparatus, such as a load702, which receives a regulated voltage Vout from the module, and a filter capacitor (C)704. Examples of the load702include an integrated circuit such as a processor or memory. In operation, a power-supply component, such as the controller710as shown inFIG. 7, controls the other power-supply component, such as the transistors712as shown inFIG. 7, to alternately couple an input voltage Vin and reference voltage (e.g., ground) to a phase inductor720in a manner that generates the regulated voltage Vout from Vin.

Still referring toFIG. 7, alternate embodiments of the system70are contemplated. For example, embodiments described above in conjunction withFIGS. 3A-5Bcan be applicable to the system70. Furthermore, although described as a buck converter, the module700can include any other type of power supply such as a buck-boost converter. Moreover, the module700can include additional components such as a filter inductor coupled between the phase inductor720and the load702. In addition, although described as being external to the module700, the filter capacitor704can be part of the module.

In summary, in the aforementioned embodiments of the present invention, since the first electronic elements can be disposed in the cavity of the second electronic element or can be disposed on the second electronic element, or the second electronic element can be stacked on the first electronic elements, compared to the conventional electronic package structures, utilization of an internal space of the electronic package structure is relatively high, so that a size of the electronic package structure can be reduced.