Patent ID: 12232302

DETAILED DESCRIPTION

In the following, details are set forth to provide a more thorough explanation of example implementations. However, it will be apparent to those skilled in the art that these implementations may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form or in a schematic view rather than in detail in order to avoid obscuring the implementations. In addition, features of the different implementations described hereinafter may be combined with each other, unless specifically noted otherwise.

Further, equivalent or like elements or elements with equivalent or like functionality are denoted in the following description with equivalent or like reference numerals. As the same or functionally equivalent elements are given the same reference numbers in the figures, a repeated description for elements provided with the same reference numbers may be omitted. Hence, descriptions provided for elements having the same or like reference numbers are mutually exchangeable.

It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).

In implementations described herein or shown in the drawings, any direct electrical connection or coupling, e.g., any connection or coupling without additional intervening elements, may also be implemented by an indirect connection or coupling, e.g., a connection or coupling with one or more additional intervening elements, or vice versa, as long as the general purpose of the connection or coupling, for example, to transmit a certain kind of signal or to transmit a certain kind of information, is essentially maintained. Features from different implementations may be combined to form further implementations. For example, variations or modifications described with respect to one of the implementations may also be applicable to other implementations unless noted to the contrary.

In the present disclosure, expressions including ordinal numbers, such as “first”, “second”, and/or the like, may modify various elements. However, such elements are not limited by the above expressions. For example, the above expressions do not limit the sequence and/or importance of the elements. The above expressions are used merely for the purpose of distinguishing an element from the other elements. For example, a first box and a second box indicate different boxes, although both are boxes. For further example, a first element could be termed a second element, and similarly, a second element could also be termed a first element without departing from the scope of the present disclosure.

Devices are becoming smaller and more compact, leading to higher power densities. A power stage module (e.g., a DC-to-DC power staging module, such as a DC/DC converter) is one example of a high-power device with a compact design. A power stage module typically includes at least one integrated power stage that contains a gate driver packaged with both high-side and low-side transistors. Large currents can be conducted through the high-side and low-side transistors. These active components generate heat while conducting the currents. Higher temperatures often accompany higher power densities. Moreover, more compact devices typically have less space and less thermal mass to absorb heat (e.g., less thermal capacitance), which can cause a thermal bottleneck. For example, some thermal dissipation paths may be smaller due to smaller spaces between components and are less efficient at dissipating heat. Accordingly, compact devices may not have enough space to store or buffer heat before the heat is able to be transferred out of the device. In some cases, fast discharge of heat may be needed to prevent overheating and component failure. Additionally, or alternatively, some thermal dissipation paths may be cut off, or blocked by other components, from cooler parts of the device or from a heat sink. Thus, it is becoming a challenge to improve thermal performances of these devices.

Some implementations disclosed herein are directed to an electronic module assembly that is dipped into a thermally conductive material in order to provide a thermally conductive coating or layer on one or more internal surfaces of the electronic module assembly and to at least partially fill one or more gaps locating internally within the electronic module assembly. Thus, the thermally conductive coating can provide one or more continuous thermal dissipation paths from a heat source to a cooler part of the electronic module assembly and/or to a heat sink of the electronic module assembly. Moreover, the thermally conductive material is an electrically isolating material that is configured to maintain electrical isolation between components of the electronic module assembly. The thermally conductive coating or layer is a one-piece integral member (e.g., formed as a one-piece integral structure) that is formed as one cohesive, continuous structure.

In some implementations, the thermally conductive coating or layer may be formed on one or more external surfaces of the electronic module assembly, thereby connecting the one or more external surfaces with the thermally conductive coating or layer arranged inside the electronic module assembly with at least one thermal dissipation path (e.g., a thermally conductive path configured to dissipate or otherwise distribute heat away from a heat source).

In some implementations, the thermally conductive coating or layer may completely fill one or more gaps located between components of the electronic module assembly by dipping the electronic module assembly in a bath or a slurry of the thermally conductive material. The thermally conductive coating or layer may be formed by dipping without masking (e.g., taping), thereby simplifying manufacturing process and lowering costs. In some implementations, the thermally conductive material may be a ceramic material (e.g., an aluminum-based ceramic, an aluminum nitride ceramic, a silicon nitride ceramic, or a silicon carbide ceramic). In some implementations, a silica coated aluminum nitride filler may be used as a core filler of the ceramic material. A liquid phase binder solution may be used to bind ceramic powder together without sintering. In this way, the binder constituents crystalize after drying (e.g., curing) and combine the ceramic powder together.

In some implementations, a viscosity of the thermally conductive coating or layer may be configured to partially fill one or more gaps or cavities and/or to entirely fill one or more gaps or cavities. For example, increasing the viscosity may enable a higher filling capability to fill or entirely fill one or more gaps or cavities. Decreasing the viscosity may decrease the filling capability of the thermally conductive material, but may save on material costs by using less material.

In some implementations, the thermally conductive coating or layer can be used to form multiple thermal dissipation paths that extend in multiple directions, in order to enhance heat dissipation in more directions.

In some implementations, the thermally conductive coating or layer may enhance electrical isolation between components of the electronic module assembly and may assist in managing creepage.

In some implementations, the thermally conductive material may have magnetic shielding properties to enhance magnetic shielding between components of the electronic module assembly.

In some implementations, the thermally conductive material may be configured to limit solder bleed if solder of the electronic module assembly is remelted during a subsequent manufacturing process or during operation of the electronic module assembly.

In some implementations, the thermally conductive coating or layer may prevent foreign material (e.g., conductive particles) from shorting components (e.g., between passive components and leads). In other words, by at least partially filling gaps between components of the electronic module assembly, the thermally conductive coating or layer may prevent shorts from forming between the components.

In some implementations, the thermally conductive coating or layer may provide the electronic module assembly with environmental protection by sealing the electronic module assembly from the environment.

In some implementations, the thermally conductive coating or layer may enable liquid cooling to be applied to the electronic module assembly while protecting the components of the electronic module assembly from the liquid (e.g., by sealing the electronic module assembly from the liquid to prevent the liquid from coming in contact with the components).

In some implementations, the thermally conductive coating or layer may structurally reinforce the electronic module assembly, which can improve an ability of the electronic module assembly to withstand drops or other types of impacts.

In some implementations, the electronic module assembly is a power stage module that is coated, at least in part, with the thermally conductive material. In some implementations, the power stage module is a voltage regulator module. The voltage regulator module may include at least one power stage that includes active devices, such as high-side and low-side transistors, that generate heat while conducting current. In some implementations, the voltage regulator module includes an inductor-cooled power stage. The voltage regulator module may include input terminals and output terminals at a same side of the voltage regulator module. An inductor embedded in a magnetic core has a first end electrically connected to switch node of a power stage included in the voltage regulator module. A conductor, such as a metal clip, may electrically connect a second end of the inductor to a power output terminal of the voltage regulator module, such that power is delivered to and from the voltage regulator module at the same side of the voltage regulator module. The inductor may provide effective cooling and a low-ohmic current path with minimum parasitic inductance. An output current may exit the power stage at one interface of the voltage regulator module and may be routed back to another interface by a low-ohmic path. More than one power stage may be included in the voltage regulator module to form a multi-phase arrangement for regulating an output voltage of a load.

FIG.1Ashows an electronic module assembly100A according to one or more implementations.FIG.1Bshows an electronic module assembly100B after a dipping process according to one or more implementations. The electronic module assembly100A is dipped into a thermally conductive material to form the electronic module assembly100B. Thus, the electronic module assembly100B includes all of the parts of the electronic module assembly100A and is described in parallel with the description of the electronic module assembly100A.

As shown inFIG.1A, the electronic module assembly100A includes a carrier substrate102, a circuit substrate104, and a passive component106. The electronic module assembly100A includes at least one active component (e.g., a transistor or a diode) that produces heat during operation. For example, an active component is a device that has an ability to amplify a signal or produce a power gain. In contrast, a passive component (e.g., a capacitor, an inductor, or a resistor) is a device that does not have the ability to amplify a signal or produce a power gain. In some implementations, the electronic module assembly100A may be a power stage module, such as a voltage regulator module.

The carrier substrate102includes a first plurality of external (e.g., exposed) surfaces, including two opposing main surfaces (e.g., a top main surface108and a bottom main surface110) and opposing side surfaces112and114. The carrier substrate102may include contact pads arranged at the bottom main surface110, including an input contact pad116that serves as a power input terminal and an output contact pad118that serves as a power output terminal. Additional contact pads, including a ground contact pad, may also be provided at the bottom main surface110. The contact pads of the carrier substrate102may be configured to be connected to a further device or interface. The carrier substrate102may include conductive interconnects that are configured to carry one or more signals between the top main surface108and the bottom main surface110. The carrier substrate102may be a system board such as a motherboard or an accelerator card with multiple processors, or an interposer such as a molded interconnect substrate, such as a printed circuit board (PCB), that attaches to a system board or another external device.

The circuit substrate104is mounted to the top main surface108of the carrier substrate102and is electrically connected to the carrier substrate102via corresponding contact pads and/or electrical (e.g., conductive) interconnect structures. For example, the circuit substrate104may be surface mounted to the top main surface108of the carrier substrate102by a plurality of electrical interconnects. The circuit substrate104comprises a second plurality of external (e.g., exposed) surfaces, including a top main surface120and opposing side surfaces122and124. The circuit substrate104may be a multi-layer PCB that includes patterned metallization layers and interconnecting vias. The circuit substrate104may include at least one active component126configured to conduct a corresponding current. For example, the at least one active component126may be electrically coupled to the carrier substrate102to receive the current from the carrier substrate (e.g., from the input contact pad116) and configured to produce heat while conducting the current.

In some implementations, the at least one active component126is a power switch (e.g., a power transistor) and the circuit substrate104includes at least two active components126. For example, the circuit substrate104may include a pair of power switches, including a high-side transistor and a low-side transistor, for each phase current. Each pair of power switches may be connected together in a half-bridge configuration at a switch node through which the phase current is conducted. Additional elements such as a gate driver, a controller, a voltage sense element, and/or a current sense element may be attached to or embedded in the circuit substrate104. Circuitry of the circuit substrate104may form a synchronous buck converter configured to receive an input voltage from the input contact pad116and provide the current (e.g., a phase current) to the passive component106at the switch node of a power stage formed by a pair of power switches.

The passive component106may be electrically coupled to the at least one active component126and configured to conduct the current received from the at least one active component126(e.g., from the switch node). The passive component106may be mounted to at least one of the carrier substrate102or the circuit substrate104. For example, the passive component106may include a first electrical interconnect128(e.g., a first pin) and a second electrical interconnect130(e.g., a second pin) that are mounted to and electrically connected with the top main surface108of the carrier substrate102. Accordingly, the passive component106may be electrically connected to the circuit substrate104by conductive paths formed by the carrier substrate102and at least one of the first electrical interconnect128or the second electrical interconnect130.

The first electrical interconnect128and the second electrical interconnect130may be arranged to straddle the circuit substrate104. In other words, the circuit substrate104may be arranged between the first electrical interconnect128and the second electrical interconnect130such that the passive component106is arranged over the circuit substrate104.

Alternatively, in some implementations, the passive component106may be electrically connected to the circuit substrate104by a metal layer formed on the top main surface120of the circuit substrate104. The metal layer may form a connection with the switch node of the circuit substrate104and the passive component106.

In some implementations, the passive component106is an inductor having a conductor132, such as a copper rod, embedded in a magnetic core134. The conductor132has a first end (e.g., a bottom end) which is electrically connected to the switch node and a second end (e.g., a top end) arranged opposite to the first end. The inductor may provide cooling and a low-ohmic current path for the current with minimum parasitic inductance.

The passive component106comprises a third plurality of external (e.g., exposed) surfaces136,138,140, and142. The passive component106may be arranged relative to the carrier substrate102and/or the circuit substrate104to form at least one gap (e.g., at least one internal gap). For example, the passive component may be arranged relative to the circuit substrate104to form at least one gap144between at least one of the second plurality of external surfaces (e.g., top main surface120) and at least one of the third plurality of external surfaces (e.g., surface142).

FIG.1Bshows the electronic module assembly100B after the electronic module assembly100A is dipped into a thermally conductive material, which is cured into a thermally conductive structure146that is formed as a one-piece integral member. The electronic module assembly100A may be dipped into the thermally conductive material one or more times to achieve a desired thickness and/or fill ratio. Accordingly, at least one of the first plurality of external surfaces of the carrier substrate102is at least partially in contact with the thermally conductive structure146, at least one of the second plurality of external surfaces of the circuit substrate104is at least partially in contact with the thermally conductive structure146, and at least one of the third plurality of external surfaces of the passive component106is at least partially in contact with the thermally conductive structure146. In addition, the thermally conductive material may at least partially fill the at least one gap144. Accordingly, the thermally conductive structure146is integrally formed as a coating on at least one of the first plurality of external surfaces, at least one of the second plurality of external surfaces, and at least one of the third plurality of external surfaces. In addition, portions of the thermally conductive structure146that form the coating are integrally formed as the one-piece integral member with portions of the thermally conductive structure146that at least partially fill the at least one gap144.

In some implementations, the bottom main surface110of the carrier substrate102may be substantially free from the thermally conductive material such that the contact pads of the carrier substrate102, including the input contact pad116and the output contact pad118, remain exposed and available for electrical contact with another device.

Because the thermally conductive structure146may be formed by dipping the electronic module assembly100A into a bath or a slurry of the thermally conductive material, the thermally conductive structure146that coats one or more surfaces and at least partially fills one or more gaps can be formed as one cohesive, continuous structure. The thermally conductive material may be in a liquid or semi-liquid state that is suitable for dipping. Because the thermally conductive structure146is formed as one cohesive, continuous structure, heat generated by the at least one active component126can be transported by one or more thermally conductive paths provided by the thermally conductive structure146. For example, the thermally conductive structure146is configured to establish at least one thermal conduit that is configured to transport the heat away from the at least one active component126toward a periphery of the electronic module assembly100B. Cooler areas of the electronic module assembly100B may use the thermally conductive structure146to draw the heat away from the at least one active component126to establish a more even distribution of heat throughout the electronic module assembly100B. The heat may be transported in multiple directions throughout the thermally conductive structure146. In other words, the thermally conductive structure146may form multiple thermal dissipation paths that extend in multiple directions in order to enhance heat dissipation in more directions. Part of the heat may be transported by the thermally conductive structure146to a heat sink. Thus, the thermally conductive structure146can be used to dissipate heat and improve thermal performance of the electronic module assembly100B.

In addition, the thermally conductive material is an electrically isolating material that is configured to maintain electrical isolation between components of the electronic module assembly100B. Thus, the thermally conductive structure146may enhance electrical isolation between components of the electronic module assembly100B and may assist in managing creepage. In addition, the thermally conductive structure146may prevent foreign material (e.g., conductive particles) from shorting components (e.g., between the passive component106and leads). In other words, by at least partially filling gaps between components of the electronic module assembly, the thermally conductive structure146may prevent shorts from forming between the components.

In some implementations, the thermally conductive material may have magnetic shielding properties. Thus, the thermally conductive structure146may enhance magnetic shielding between components of the electronic module assembly100B.

In some implementations, the thermally conductive material may be configured to limit solder bleed. Thus, the thermally conductive structure146may prevent or reduce solder bleeding, if, for example, solder of the electronic module assembly is remelted during a subsequent manufacturing process or during operation of the electronic module assembly.

In some implementations, the thermally conductive structure146may provide the electronic module assembly with environmental protection by sealing at least a portion of the electronic module assembly100B from the environment.

In some implementations, the thermally conductive structure146may enable liquid cooling to be applied to the electronic module assembly100B while protecting the components of the electronic module assembly100B from the liquid (e.g., by at least partially sealing the electronic module assembly from the liquid in order to prevent the liquid from coming in contact with the components).

In some implementations, the thermally conductive structure146may structurally reinforce the electronic module assembly100B, which can improve an ability of the electronic module assembly100B to withstand drops or other types of collisions.

In some implementations, by dipping the electronic module assembly100A in the bath or the slurry of the thermally conductive material, the thermally conductive structure146may completely fill one or more gaps located between components of the electronic module assembly. The thermally conductive coating may be formed by dipping without masking (e.g., taping), thereby simplifying a manufacturing process and lowering costs. In some implementations, the thermally conductive material may be a ceramic material (e.g., an aluminum-based ceramic, an aluminum nitride ceramic, a silicon nitride ceramic, or a silicon carbide ceramic). In some implementations, a silica coated aluminum nitride filler may be used as a core filler of the ceramic material. A liquid phase binder solution may be used to bind ceramic powder together without sintering. In this way, the binder constituents crystalize after drying (e.g., curing) and combine the ceramic powder together. In other words, a binder coating on ceramic powder and a respective liquid solution can be used to fuse ceramic powder together. In some implementations, the liquid phase binder solution may be water, which may advantageously be cured without high temperatures. In some implementations, a binder includes a solid phase, such as an inorganic oxide layer as seed, and a liquid phase, such as a solution of inorganic salt solution for hydrothermal sintering. It will be appreciated that other types of ceramic materials, core fillers, and/or binders may be used for the thermally conductive material and it is not limited to the examples described herein.

In some implementations, a viscosity of the thermally conductive structure146may be configured to partially fill one or more gaps or cavities and/or to entirely fill one or more gaps or cavities. For example, increasing the viscosity of the thermally conductive material for a dipping process may enable a higher filling capability, to fill or entirely fill one or more gaps or cavities. In contrast, decreasing the viscosity of the thermally conductive material for the dipping process may decrease the filling capability of the thermally conductive material, but may save on material costs by using less material.

As indicated above,FIGS.1A and1Bare provided merely as examples. Other examples are possible and may differ from what was described with regard toFIGS.1A and1B. The number and arrangement of components shown inFIGS.1A and1Bare provided as an example. In practice, the electronic module assemblies100A and100B may include additional components, fewer components, different components, or differently arranged components than those shown inFIGS.1A and1B. Two or more components shown inFIGS.1A and1Bmay be implemented within a single component, or a single component shown inFIGS.1A and1Bmay be implemented as multiple, distributed components. Additionally, or alternatively, a set of components (e.g., one or more components) of the electronic module assemblies100A and100B may perform one or more functions described as being performed by another set of components of the electronic module assemblies100A and100B.

FIG.2Ashows an electronic module assembly200A according to one or more implementations. The electronic module assembly200A includes the carrier substrate102, the circuit substrate104, and the passive component106, as similarly described in connection withFIGS.1A and1B. Additionally, the electronic module assembly200A includes a conductor structure202, a thermal interface material204that is electrically insulative, such as a silicone-based or synthetic-based thermal compound, and a heat sink206.

The conductor structure202may have a U-shape. The conductor structure202may include a main body208, a first leg210that extends from the main body208to a first conductor end212of the conductor structure202, and a second leg214that extends from the main body208to a second conductor end216of the conductor structure202. In addition, the main body208, the first leg210, and the second leg214may define an internal area218in which the circuit substrate104and the passive component106are arranged. Surfaces of one or more components of the electronic module assembly200A that are located inside the internal area218that are exposed for contact with a thermally conductive material during dipping may be referred to as “internal exposed surfaces.” Surfaces of one or more components of the electronic module assembly200A that are located outside of the internal area218that are exposed for contact with a thermally conductive material during dipping may be referred to as “external exposed surfaces.”

The first conductor end212of the conductor structure202may be coupled to a first peripheral region219of the carrier substrate102by a first contact structure220. The first contact structure220may be made of an electrically conductive material (e.g., metal) that forms an electrical connection with the first conductor end212of the conductor structure202and the carrier substrate102. The second conductor end216of the conductor structure202may be coupled to a second peripheral region222of the carrier substrate102by a second contact structure224. The second contact structure224may be made of an electrically conductive material (e.g., metal) that forms an electrical connection with the second conductor end216of the conductor structure202and the carrier substrate102. The first peripheral region219and the second peripheral region222are arranged at opposite sides of the carrier substrate102.

The conductor structure202may be a metal clip. The conductor structure202may cover the power stage of the electronic module assembly200A and form an electromagnetic shield for the passive component106(e.g., an inductor) and the active components126of the power stage. For example, the conductor structure202may be configured as a Faraday cage for potentially disturbing electro-magnetic emissions, for example, from switching of the power switches included in the power stage.

The second end (e.g., the top end) of the conductor132may be electrically coupled to the main body208of the conductor structure202. For example, a coupling structure226, such as solder, an electrically conductive adhesive, or an electrically conductive paste, may be interposed between and in contact with the main body208of the conductor structure202and the second end (e.g., the top end) of the conductor132, to electrically couple the second end (e.g., the top end) of the conductor132and the main body208of the conductor structure202.

The passive component106may receive a current/(e.g., a phase current) from the switch node of the circuit substrate104. For example, the conductor132of the passive component106may receive the current/from an electrical path formed through the circuit substrate104, the carrier substrate102, and the second electrical interconnect130of the passive component.

As described in connection withFIGS.1A and1B, the current/may be derived from the input voltage provided to the input contact pad116. The conductor132of the passive component106may provide the current/to the conductor structure202, and the conductor structure202may provide the current to the output contact pad118of the carrier substrate102. Accordingly, the current flows through the conductor132of the passive component106, through the coupling structure226, through part of the main body208of the conductor structure202, through the first leg210of the conductor structure202, through the first contact structure220, and through the first peripheral region of the carrier substrate102to the output contact pad118. The current/is output from the electronic module assembly200A as an output current by the output contact pad118. In some implementations, the output current exits the electronic module assembly200A at the output contact pad118and is routed back to the input contact pad116by a low-ohmic path.

Accordingly, the passive component106may provide cooling and a low-ohmic current path for the current/with minimum parasitic inductance. Thus, the conductor structure202electrically connects the second end (e.g., the top end) of the conductor132of the passive component106(e.g., an inductor) to the power output terminal located at the output contact pad118such that input power is delivered to the electronic module assembly200A at the input contact pad116and output power is delivered from the electronic module assembly200A at the output contact pad118at a same side (e.g., the bottom main surface110) of the electronic module assembly200A. The heat sink206may be in thermal contact with the main body of the conductor structure202. The heat sink206may be air cooled or liquid cooled. In some implementations, the heat sink206may be electrically isolated from the conductor structure202by the thermal interface material204. The active components126may be cooled through the conductor structure202coupling the switch node to the passive component106and through the passive component106toward the heat sink206attached to an opposite side of the electronic module assembly200A from the side with the input contact pad116and the output contact pad118.

The electronic module assembly200A may be dipped into a thermally conductive material one or more times, as similarly described in connection withFIGS.1A and1B, which is cured to form a thermally conductive structure228. Accordingly, at least one of the first plurality of external surfaces of the carrier substrate102is at least partially in contact with the thermally conductive structure228, at least one of the second plurality of external surfaces of the circuit substrate104is at least partially in contact with the thermally conductive structure228, and at least one of the third plurality of external surfaces of the passive component106is at least partially in contact with the thermally conductive structure228. In addition, the conductor structure202includes a fourth plurality of external surfaces, including surfaces230and232. At least one of the fourth plurality of external surfaces of the thermally conductive structure228is at least partially in contact with the thermally conductive structure228. In addition, the thermally conductive material of the thermally conductive structure228may at least partially fill the gap144. In addition, the thermally conductive material of the thermally conductive structure228may at least partially fill the internal area218. In some implementations, the thermally conductive structure228may entirely fill the gap144. In some implementations, the thermally conductive structure228may entirely fill the internal area218. In some implementations, the thermally conductive structure228may coat all surfaces that are exposed during dipping, with the exception of the bottom main surface110of the carrier substrate102, such that the contact pads are not covered by the thermally conductive material of the thermally conductive structure228.

Because the thermally conductive structure228may be formed by dipping the electronic module assembly200A into a bath or a slurry of the thermally conductive material, the thermally conductive structure228that coats one or more surfaces and at least partially fills one or more gaps can be formed as one cohesive, continuous structure. Because the thermally conductive structure228is formed as one cohesive, continuous structure, heat generated by the at least one active component126can be transported by one or more thermally conductive paths provided by the thermally conductive structure228. For example, the thermally conductive structure228is configured to establish at least one thermal conduit that is configured to transport the heat away from the at least one active component126toward a periphery of the electronic module assembly200A. Cooler areas of the electronic module assembly200A may use the thermally conductive structure228to draw the heat away from the at least one active component126to establish a more even distribution of heat throughout the electronic module assembly200A. The heat may be transported in multiple directions throughout the thermally conductive structure228. In other words, the thermally conductive structure228may form multiple thermal dissipation paths that extend in multiple directions in order to enhance heat dissipation in more directions. Part of the heat may be transported by the thermally conductive structure228to the conductor structure202and/or to the heat sink206. The conductor structure202may also be configured to further distribute heat, received from the thermally conductive structure228, to cooler areas of the electronic module assembly200A, including to cooler portions of the conductor structure202and/or to the heat sink206. Thus, the thermally conductive structure228can be used to dissipate heat and improve thermal performance of the electronic module assembly200A.

As indicated above,FIG.2Ais provided merely as an example. Other examples are possible and may differ from what was described with regard toFIG.2A. The number and arrangement of components shown inFIG.2Aare provided as an example. In practice, the electronic module assembly200A may include additional components, fewer components, different components, or differently arranged components than those shown inFIG.2A. Two or more components shown inFIG.2Amay be implemented within a single component, or a single component shown inFIG.2Amay be implemented as multiple, distributed components. Additionally, or alternatively, a set of components (e.g., one or more components) of the electronic module assembly200A may perform one or more functions described as being performed by another set of components of the electronic module assembly200A.

FIG.2Bshows an electronic module assembly200B according to one or more implementations. The electronic module assembly200B is similar to the electronic module assembly200A described in connection withFIG.2A, with the exception that the electronic module assembly200B does not include the thermal interface material204or the heat sink206. Accordingly, the thermally conductive structure228may be in contact with a top portion of the conductor structure202.

In some implementations, the thermal interface material204and/or the heat sink206may be disposed on top of the thermally conductive structure228.

FIG.2Bis provided merely as an example. Other examples are possible and may differ from what was described with regard toFIG.2B. The number and arrangement of components shown inFIG.2Bare provided as an example. In practice, the electronic module assembly200B may include additional components, fewer components, different components, or differently arranged components than those shown inFIG.2B. Two or more components shown inFIG.2Bmay be implemented within a single component, or a single component shown inFIG.2Bmay be implemented as multiple, distributed components. Additionally, or alternatively, a set of components (e.g., one or more components) of the electronic module assembly200B may perform one or more functions described as being performed by another set of components of the electronic module assembly200B.

FIG.3Ashows an electronic module assembly300according to one or more implementations.FIG.3Bshows the electronic module assembly300according to one or more implementations, with some aspects removed to provide visibility to some components that are hidden from view inFIG.3A, such as conductive interconnects and the conductor132of the passive component106.

The electronic module assembly300includes the carrier substrate102, the circuit substrate104, and the passive component106(e.g., an inductor), as similarly described in connection withFIGS.1A and1B. Additionally, the electronic module assembly300includes the conductor structure202, the internal area218, and the thermally conductive structure228, as similarly described in connection withFIGS.2A and2B. Additionally, the electronic module assembly300may include the thermal interface material204and the heat sink206disposed on the thermally conductive structure228in a region of the thermally conductive structure228that is formed on top of the main body208of the conductor structure202.

The circuit substrate104includes a first active component126a(e.g., a high-side power transistor) and a second active component126b(e.g., a low-side power transistor) that are coupled by switch node302to form a transistor half-bridge.

The electronic module assembly300may include a metallization layer304formed on the top main surface120of the circuit substrate104. The metallization layer304is arranged between the circuit substrate104and the passive component106. In particular, the metallization layer304is electrically coupled to the switch node302and the conductor132of the passive component106, and is configured to provide an electrical path for the current/to flow from the switch node302to the conductor132of the passive component106.

The electronic module assembly300may include additional circuit components306,308, and/or310. For example, each of the additional circuit components306,308, and/or310may be a passive component (e.g., a capacitor or a resistor) or an active component. The additional circuit component306may be coupled to the top main surface108of the carrier substrate102. The additional circuit component308may be embedded in the circuit substrate104. The additional circuit component310may be coupled to the top main surface120of the circuit substrate104. Each of the additional circuit components306,308, and/or310may be in contact with the thermally conductive structure228.

The electronic module assembly300may include an interface312coupled to the bottom main surface110of the carrier substrate102. The interface312may receive the output current from the output contact pad118and may provide a low-ohmic path for routing the output current back to the input contact pad116.

The thermally conductive structure228is formed on one or more surfaces of the electronic module assembly300and at least partially fills one or more gaps between components of the electronic module assembly300. The thermally conductive structure228may partially fill or completely fill the internal area218. In some implementations, the thermally conductive structure228may fill small gaps or small cavities and may only partially fill large gaps or large cavities.

As indicated above,FIGS.3A and3Bare provided merely as examples. Other examples are possible and may differ from what was described with regard toFIGS.3A and3B. The number and arrangement of components shown inFIGS.3A and3Bare provided as an example. In practice, the electronic module assembly300may include additional components, fewer components, different components, or differently arranged components than those shown inFIGS.3A and3B. Two or more components shown inFIGS.3A and3Bmay be implemented within a single component, or a single component shown inFIGS.3A and3Bmay be implemented as multiple, distributed components. Additionally, or alternatively, a set of components (e.g., one or more components) of the electronic module assembly300may perform one or more functions described as being performed by another set of components of the electronic module assembly300.

FIG.4shows a flow diagram of a process400according to one or more implementations. The process400may be used to manufacture one of the electronic module assemblies described herein, including electronic module assembly100B,200A,200B, or300. In this example, the electronic module assemblies100A and100B are illustrated. After the components of the electronic module assembly100A are assembled, the electronic module assembly100A is partially dipped into a thermally conductive slurry or a thermally conductive liquid of a thermally conductive material to coat one or more of a plurality of internal exposed surfaces and one or more of a plurality of external exposed surfaces of the electronic module assembly100A with the thermally conductive material (step410).

In some implementations, the electronic module assembly100A may be dipped into the thermally conductive material with the bottom main surface110of the carrier substrate102facing out of the thermally conductive material to prevent the contact pads provided at the bottom main surface110from being covered in the thermally conductive material. In addition, during step410at least one internal gap or cavity of the electronic module assembly100A is at least partially filled with the thermally conductive material.

In some implementations, step410may be repeated one or more times such that the electronic module assembly100A may be dipped into the thermally conductive material multiple times to increase a thickness of the coating and/or to increase a fill ratio of one or more internal gaps or cavities.

In step420, the electronic module assembly100A is pulled out of the thermally conductive material and the thermally conductive material formed on the electronic module assembly100A is cured to form the electronic module assembly100B that includes the thermally conductive structure146. The thermally conductive structure146is formed as a one-piece integral member, as described herein. The thermally conductive structure146is contiguously formed as a coating that is in contact with the exposed surfaces and as a filler that at least partially filled at least one gap or cavity. A viscosity of the thermally conductive material may be high enough that the exposed surfaces of the electronic module assembly100A remain coated with the thermally conductive material and the at least one internal gap or cavity of the electronic module assembly100A remains at least partially filled with the thermally conductive material. The thermally conductive material formed on the electronic module assembly100A is cured by a drying process, which may include an application of heat to accelerate the curing process.

In some implementations, additional processing steps may be performed to fill or partially fill any remaining gaps. For example, an additional thermally conductive material may be deposited, injected, or otherwise formed within one or more remaining internal gaps or cavities to at least partially fill or completely fill up the remaining internal gaps or cavities within electronic module assembly100B. For example, plating may be performed to at least partially fill or completely fill up the remaining internal gaps or cavities within electronic module assembly100B with the additional thermally conductive material. The additional thermally conductive material may be used to enhance heat dissipation and improve thermal performance of the electronic module assembly100B.

AlthoughFIG.4shows example blocks of process400, in some implementations, process400includes additional steps, fewer steps, different steps, or differently arranged steps than those depicted inFIG.4.

FIG.5shows a flow diagram of a process500according to one or more implementations. The process500may be used to manufacture one of the electronic module assemblies described herein, including electronic module assembly100B,200A,200B, or300. In this example, the electronic module assemblies100A and100B are illustrated.

In step510, the components of the electronic module assembly100A are assembled.

In step520, the electronic module assembly100A is fully dipped (e.g., fully submerged) into a thermally conductive slurry or a thermally conductive liquid of a thermally conductive material to coat one or more of a plurality of internal exposed surfaces and one or more of a plurality of external exposed surfaces of the electronic module assembly100A with the thermally conductive material. In addition, during step520, at least one internal gap or cavity of the electronic module assembly100A is at least partially filled with the thermally conductive material. In some implementations, step520may be repeated one or more times such that the electronic module assembly100A may be dipped into the thermally conductive material multiple times to increase a thickness of the coating and/or to increase a fill ratio of one or more internal gaps or cavities.

In step530, the electronic module assembly100A is pulled out of the thermally conductive material and the thermally conductive material formed on the electronic module assembly100A is cured to form the electronic module assembly100B that includes the thermally conductive structure146. The thermally conductive structure146is formed as a one-piece integral member, as described herein. The thermally conductive structure146is contiguously formed as a coating that is in contact with the exposed surfaces and as a filler that at least partially fills at least one gap or cavity. A viscosity of the thermally conductive material may be high enough that the exposed surfaces of the electronic module assembly100A remain coated with the thermally conductive material and the at least one internal gap or cavity of the electronic module assembly100A remains at least partially filled with the thermally conductive material. The thermally conductive material formed on the electronic module assembly100A is cured by a drying process, which may include an application of heat to accelerate the curing process.

In step540, the thermally conductive structure146is removed from the bottom main surface110of the carrier substrate102to expose the contact pads, including the input contact pad116and the output contact pad118.

In some implementations, additional processing steps may be performed to fill or partially fill any remaining gaps. For example, an additional thermally conductive material may be deposited, injected, or otherwise formed within one or more remaining internal gaps or cavities to at least partially fill or completely fill up the remaining internal gaps or cavities within electronic module assembly100B. For example, plating may be performed to at least partially fill or completely fill up the remaining internal gaps or cavities within electronic module assembly100B with the additional thermally conductive material. The additional thermally conductive material may be used to enhance heat dissipation and improve thermal performance of the electronic module assembly100B.

AlthoughFIG.5shows example blocks of process500, in some implementations, process500includes additional steps, fewer steps, different steps, or differently arranged steps than those depicted inFIG.5.

The following provides an overview of some Aspects of the present disclosure:Aspect 1: An electronic module assembly, comprising: a thermally conductive material formed as a one-piece integral member; a carrier substrate comprising a first plurality of external surfaces, wherein at least one of the first plurality of external surfaces is at least partially in contact with the thermally conductive material; a circuit substrate mounted to the carrier substrate, wherein the circuit substrate comprises a second plurality of external surfaces, wherein at least one of the second plurality of external surfaces is at least partially in contact with the thermally conductive material, wherein the circuit substrate comprises at least one active component configured to conduct a current, and wherein the at least one active component is electrically coupled to the carrier substrate and is configured to produce heat while conducting the current; and a passive component electrically coupled to the at least one active component and configured to conduct the current, wherein the passive component is mounted to at least one of the carrier substrate or the circuit substrate, and wherein the passive component comprises a third plurality of external surfaces, wherein at least one of the third plurality of external surfaces is at least partially in contact with the thermally conductive material, wherein the passive component is arranged relative to the circuit substrate to form at least one gap between at least one of the second plurality of external surfaces and at least one of the third plurality of external surfaces, wherein the thermally conductive material is integrally formed as a coating on the first plurality of external surfaces, the second plurality of external surfaces, and the third plurality of external surfaces, and integrally formed with the coating as the one-piece integral member to at least partially fill the at least one gap, and wherein the thermally conductive material is configured to establish at least one thermal conduit that is configured to transport the heat away from the at least one active component toward a periphery of the electronic module assembly.Aspect 2: The electronic module assembly of Aspect 1, further comprising: at least one heat sink, wherein the at least one thermal conduit is configured to transport the heat away from the at least one active component to the at least one heat sink.Aspect 3: The electronic module assembly of Aspect 3, wherein: the at least one gap is at least one first gap, at least one second gap is formed between the at least one active component and the at least one heat sink, and the thermally conductive material is contiguously formed with the coating to fill the at least one second gap.Aspect 4: The electronic module assembly of any of Aspects 1-3, wherein the thermally conductive material is an electrically isolating material.Aspect 5: The electronic module assembly of any of Aspects 1-4, wherein the circuit substrate includes a power stage comprising the at least one active component.Aspect 6: The electronic module assembly of Aspect 5, wherein the power stage comprises a transistor half-bridge and driving circuitry configured to drive the transistor half-bridge.Aspect 7: The electronic module assembly of any of Aspects 1-6, wherein: the passive component is mounted to a surface of the second plurality of external surfaces of the carrier substrate by a first plurality of electrical interconnects, wherein the first plurality of electrical interconnects includes a first subset of electrical interconnects and a second subset of electrical interconnects, wherein the circuit substrate is straddled between the first subset of electrical interconnects and the second subset of electrical interconnects.Aspect 8: The electronic module assembly of Aspect 7, wherein the circuit substrate is arranged relative to the passive component such that the at least one gap is formed between the circuit substrate and the passive component.Aspect 9: The electronic module assembly of Aspect 7, wherein the circuit substrate is surface mounted to the surface of the carrier substrate by a second plurality of electrical interconnects.Aspect 10: The electronic module assembly of any of Aspects 1-9, further comprising: a conductor structure having a U-shape, the conductor structure comprising a main body, a first leg that extends from the main body to a first conductor end of the conductor structure, and a second leg that extends from the main body to a second conductor end of the conductor structure, wherein the main body, the first leg, and the second leg define an internal area, wherein the carrier substrate comprises a first peripheral region and a second peripheral region arranged opposite to the first peripheral region, wherein the first conductor end of the conductor structure is coupled to the first peripheral region of the carrier substrate, wherein the second conductor end of the conductor structure is coupled to the second peripheral region of the carrier substrate, and wherein the circuit substrate and the passive component are arranged within the internal area.Aspect 11: The electronic module assembly of Aspect 10, wherein the conductor structure is in contact with the thermally conductive material, wherein the at least one thermal conduit is configured to transport a portion of the heat to the conductor structure.Aspect 12: The electronic module assembly of Aspect 10, wherein the conductor structure includes a fourth plurality of external surfaces, wherein at least one of the fourth plurality of external surfaces is at least partially in contact with the thermally conductive material, wherein the thermally conductive material is integrally formed as part of the coating on the at least one of the fourth plurality of external surfaces.Aspect 13: The electronic module assembly of Aspect 12, wherein the thermally conductive material is integrally formed with the coating as the one-piece integral member to fill the internal area.Aspect 14: The electronic module assembly of Aspect 10, further comprising: a heat sink in thermal contact with the main body of the conductor structure.Aspect 15: The electronic module assembly of Aspect 10, further wherein the main body of the conductor structure is electrically connected to the passive component and is configured to conduct the current.Aspect 16: An electronic module assembly, comprising: a thermally conductive material formed as a one-piece integral member; a carrier substrate comprising a first plurality of external surfaces, wherein at least one of the first plurality of external surfaces is at least partially in contact with the thermally conductive material; a circuit substrate mounted to the carrier substrate, wherein the circuit substrate comprises a second plurality of external surfaces, wherein at least one of the second plurality of external surfaces is at least partially in contact with the thermally conductive material, wherein the circuit substrate comprises at least one active component electrically coupled to the carrier substrate and configured to produce heat while operating; and a conductor structure having a U-shape, the conductor structure comprising a main body, a first leg that extends from the main body to a first conductor end of the conductor structure, and a second leg that extends from the main body to a second conductor end of the conductor structure, wherein the main body, the first leg, and the second leg define an internal area, and wherein the conductor structure includes a third plurality of external surfaces, wherein the carrier substrate comprises a first peripheral region and a second peripheral region arranged opposite to the first peripheral region, wherein the first conductor end of the conductor structure is coupled to the first peripheral region of the carrier substrate, wherein the second conductor end of the conductor structure is coupled to the second peripheral region of the carrier substrate, wherein the circuit substrate is arranged within the internal area, wherein the thermally conductive material is integrally formed as a coating on the at least one of the first plurality of external surfaces, the at least one of the second plurality of external surfaces, and at least one of the third plurality of external surfaces, and wherein the thermally conductive material is configured to establish at least one thermal conduit that is configured to transport the heat away from the at least one active component to the conductor structure.Aspect 17: A method of manufacturing an electronic module assembly, the method comprising: forming the electronic module assembly, wherein the electronic module assembly comprises a plurality of internal exposed surfaces, a plurality of external exposed surfaces, at least one internal cavity, and an internal heat source configured to generate heat internally within the electronic module assembly; dipping the electronic module assembly into a thermally conductive material to coat the plurality of internal exposed surfaces and the plurality of external exposed surfaces and to at least partially fill the at least one internal cavity; and curing the thermally conductive material formed on the plurality of internal exposed surfaces and the plurality of external exposed surfaces and filled within the at least one internal cavity to form a thermally conductive layer, wherein the thermally conductive layer is formed as a one-piece integral member. The thermally conductive material may be a thermally conductive slurry or a flowable thermally conductive liquid.Aspect 18: The method of Aspect 17, wherein forming the electronic module assembly comprises: forming a circuit substrate onto a carrier substrate, wherein the carrier substrate comprises a first peripheral region and a second peripheral region arranged opposite to the first peripheral region, and wherein the circuit substrate comprises the internal heat source; and coupling a conductor structure to the carrier substrate, wherein the conductor structure has a U-shape, the conductor structure comprising a main body, a first leg that extends from the main body to a first conductor end of the conductor structure, and a second leg that extends from the main body to a second conductor end of the conductor structure, wherein the main body, the first leg, and the second leg define an internal area, and wherein coupling the conductor structure to the carrier substrate includes coupling the first conductor end of the conductor structure to the first peripheral region of the carrier substrate and coupling the second conductor end of the conductor structure to the second peripheral region of the carrier substrate such that the circuit substrate is arranged within the internal area.Aspect 19: The method of Aspect 18, wherein forming the electronic module assembly comprises: electrically connecting the conductor structure to the circuit substrate.Aspect 20: The method of Aspect 18, wherein: the plurality of internal exposed surfaces and the plurality of external exposed surfaces are formed by exposed surfaces of the circuit substrate, the carrier substrate, and the conductor structure, and the thermally conductive layer coats the conductor structure and fills at least part of the internal area.Aspect 21: The method of Aspect 20, wherein the least one internal cavity includes the internal area.Aspect 22: The method of any of Aspects 17-21, wherein the electronic module assembly comprises a plurality of contact pads arranged at a surface of the plurality of external exposed surfaces, and the method further comprises: removing a portion of the thermally conductive layer from the surface to expose the plurality of contact pads.Aspect 23: The method of any of Aspects 17-22, wherein the thermally conductive material is an electrically isolating material.Aspect 24: A system configured to perform one or more operations recited in one or more of Aspects 17-23.Aspect 25: An apparatus comprising means for performing one or more operations recited in one or more of Aspects 17-23.Aspect 26: A non-transitory computer-readable medium storing a set of instructions, the set of instructions comprising one or more instructions that, when executed by a device, cause the device to perform one or more operations recited in one or more of Aspects 17-23.Aspect 27: A computer program product comprising instructions or code for executing one or more operations recited in one or more of Aspects 17-23.

The foregoing disclosure provides illustration and description but is not intended to be exhaustive or to limit the implementations to the precise forms disclosed. Modifications and variations may be made in light of the above disclosure or may be acquired from practice of the implementations described herein.

Each of the illustrated x-axis, y-axis, and z-axis is substantially perpendicular to the other two axes. In other words, the x-axis is substantially perpendicular to the y-axis and the z-axis, the y-axis is substantially perpendicular to the x-axis and the z-axis, and the z-axis is substantially perpendicular to the x-axis and the y-axis. In some cases, a single reference number is shown to refer to a surface, or fewer than all instances of a part may be labeled with all surfaces of that part. All instances of the part may include associated surfaces of that part despite not every surface being labeled.

The orientations of the various elements in the figures are shown as examples, and the illustrated examples may be rotated relative to the depicted orientations. The descriptions provided herein, and the claims that follow, pertain to any structures that have the described relationships between various features, regardless of whether the structures are in the particular orientation of the drawings, or are rotated relative to such orientation. Similarly, spatially relative terms, such as “top,” “bottom,” “below,” “beneath,” “lower,” “above,” “upper,” “middle,” “left,” and “right,” are used herein for ease of description to describe one element's relationship to one or more other elements as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the element, structure, and/or assembly in use or operation in addition to the orientations depicted in the figures. A structure and/or assembly may be otherwise oriented (rotated 90 degrees or at other orientations), and the spatially relative descriptors used herein may be interpreted accordingly. Furthermore, the cross-sectional views in the figures only show features within the planes of the cross-sections, and do not show materials behind the planes of the cross-sections, unless indicated otherwise, in order to simplify the drawings.

As used herein, the terms “substantially” and “approximately” mean “within reasonable tolerances of manufacturing and measurement.” For example, the terms “substantially” and “approximately” may be used herein to account for small manufacturing tolerances or other factors (e.g., within 5%) that are deemed acceptable in the industry without departing from the aspects of the implementations described herein. For example, a resistor with an approximate resistance value may practically have a resistance within 5% of the approximate resistance value. As another example, an approximate signal value may practically have a signal value within 5% of the approximate signal value.

Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of implementations described herein. Many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. For example, the disclosure includes each dependent claim in a claim set in combination with every other individual claim in that claim set and every combination of multiple claims in that claim set. As used herein, a phrase referring to “at least one of” a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover a, b, c, a+b, a+c, b+c, and a+b+c, as well as any combination with multiples of the same element (e.g., a+a, a+a+a, a+a+b, a+a+c, a+b+b, a+c+c, b+b, b+b+b, b+b+c, c+c, and c+c+c, or any other ordering of a, b, and c).

Further, it is to be understood that the disclosure of multiple acts or functions disclosed in the specification or in the claims may not be construed as to be within the specific order. Therefore, the disclosure of multiple acts or functions will not limit these to a particular order unless such acts or functions are not interchangeable for technical reasons. Furthermore, in some implementations, a single act may include or may be broken into multiple sub acts. Such sub acts may be included and part of the disclosure of this single act unless explicitly excluded.

No element, act, or instruction used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items and may be used interchangeably with “one or more.” Further, as used herein, the article “the” is intended to include one or more items referenced in connection with the article “the” and may be used interchangeably with “the one or more.” Where only one item is intended, the phrase “only one,” “single,” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms that do not limit an element that they modify (e.g., an element “having” A may also have B). Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. As used herein, the term “multiple” can be replaced with “a plurality of” and vice versa. Also, as used herein, the term “or” is intended to be inclusive when used in a series and may be used interchangeably with “and/or,” unless explicitly stated otherwise (e.g., if used in combination with “either” or “only one of”).