This application claims the priority benefits of Taiwan application serial no. 107121274, filed on Jun. 21, 2018. The disclosure of which is hereby incorporated by reference herein in its entirety.
The disclosure is related to a power device and more particularly, to a power device for rectifier.
In the existing vehicle transportation system, since the efficiency and life of an alternating current generator are much higher than that of a direct current generator, the current vehicle generators are all alternating current generators. In order to charge the alternating current generated by the alternating current generator into the battery, a rectifier diode is used to rectify the alternating current into direct current. As such, the electric power is supplied for various electrical devices in the vehicle system to operate continuously, and the vehicle can run without consuming the electric power stored in the battery, so as to keep abundant electric power in the battery for the next run. In general, 6 to 8 rectifier diodes are usually disposed on the electrode plates of an alternating current generator.
In the past, a PN junction diode was often used as a rectifier diode. However, the PN junction diode has a rather high forward voltage (VF), which easily causes the problem of power conversion loss.
Therefore, a rectifier diode using a metal oxide semiconductor field effect transistor (MOSFET) to perform synchronous rectifying has been developed recently. Since the MOSFET has no built-in potential and has a low VF, the loss is also low. However, driving the MOSFET needs additional control integrated circuit and so on to form a circuit system, the interconnection inner the circuit system is often complicated resulting in high parasitic effect, which affect the efficiency of the rectifier.
The disclosure provides a power device for rectifier having a circuit system with low parasitic effect and capable of further decreasing the VF and thereby improving the efficiency of the rectifier.
A power device for rectifier of the disclosure includes a first terminal and a second terminal adapted for connecting an external circuit, and a circuit system located between the first terminal and the second terminal. The circuit system is electrically connected to the first terminal and the second terminal. The circuit system includes a pre-molded chip and a control device. The pre-molded chip includes a transistor and a first encapsulant, wherein the transistor has a first electrode, a second electrode and a third electrode, and the first encapsulant is adapted for encapsulating the transistor. The first terminal, the second terminal and the control device are respectively electrically connected to the first electrode, the second electrode and the third electrode of the transistor.
In an embodiment of the disclosure, the pre-molded chip further includes a patterned circuit layer electrically connected to at least one of the first electrode, the second electrode and the third electrode of the transistor, and the first encapsulant encapsulates the patterned circuit layer and exposes a part of the patterned circuit layer.
In an embodiment of the disclosure, the patterned circuit layer is electrically connected to the first electrode and the third electrode, and the first terminal and the control device are respectively electrically connected to the first electrode and the third electrode via the exposed part of the patterned circuit layer.
In an embodiment of the disclosure, the pre-molded chip encapsulated by the first encapsulant exposes the second electrode electrically connected to the second terminal.
In an embodiment of the disclosure, a material of the first terminal and a material of the second terminal comprise aluminum, copper or an alloy thereof.
In an embodiment of the disclosure, the transistor is a field effect transistor controlled by voltage or current.
In an embodiment of the disclosure, the transistor is a metal oxide semiconductor field effect transistor, an insulated gate bipolar transistor or a gallium nitride transistor.
In an embodiment of the disclosure, a material of the first encapsulant includes an epoxy resin, a silicone resin, a biphenyl resin, an unsaturated polyester or a ceramic material.
In an embodiment of the disclosure, the first terminal includes a base and a lead, a shape of a bottom surface of the base is a circle, a square or a hexagon and a shape of the second terminal is a circle, a square or a hexagon.
In an embodiment of the disclosure, the power device for rectifier may further include a conductive spacer, located between the pre-molded chip and the first terminal and adapted for electrically connecting the pre-molded chip and the first terminal.
In an embodiment of the disclosure, the conductive spacer and the first terminal are integrally formed.
In an embodiment of the disclosure, the power device for rectifier may further include a second encapsulant, located on the second terminal and adapted for covering the conductive spacer, the circuit system and a part of the first terminal.
In an embodiment of the disclosure, the power device for rectifier may further include a second encapsulant, located between the pre-molded chip and the first terminal and adapted for encapsulating the control device and the conductive spacer and exposing a part of the conductive spacer.
In an embodiment of the disclosure, the power device for rectifier may further include a bonding material, located between the second encapsulant and the first terminal.
In an embodiment of the disclosure, the power device for rectifier further includes a third encapsulant, located on the second terminal and adapted for covering the conductive spacer, the circuit system and a part of the first terminal.
In an embodiment of the disclosure, a material of the second encapsulant and a material of the third encapsulant comprise an epoxy resin, a silicone resin, a biphenyl resin, an unsaturated polyester or a ceramic material.
Another power device for rectifier of the disclosure includes a first terminal and a second terminal adapted for connecting an external circuit, and a pre-molded chip located between the first terminal and the second terminal. The pre-molded chip includes a transistor and a first encapsulant, wherein the transistor has a first electrode and a second electrode, and the first encapsulant is adapted for encapsulating the transistor, and wherein the first terminal and the second terminal are respectively electrically connected to the first electrode of the transistor and the second electrode of the transistor.
In another embodiment of the disclosure, the pre-molded chip further includes a patterned circuit layer electrically connected to the first electrode, wherein the first encapsulant encapsulates the patterned circuit layer and exposes a part of the patterned circuit layer, and the first terminal is electrically connected to the first electrode via the exposed part of the patterned circuit layer.
In another embodiment of the disclosure, the pre-molded chip exposes the second electrode electrically connected to the second terminal.
In another embodiment of the disclosure, a material of the first terminal and a material of the second terminal comprise aluminum, copper or an alloy thereof.
In another embodiment of the disclosure, a material of the first encapsulant includes an epoxy resin, a silicone resin, a biphenyl resin, an unsaturated polyester or a ceramic material.
A rectifier device of a vehicle generator of the disclosure includes the aforementioned power device for rectifier.
Based on the above, the circuit system in the power device for rectifier of the disclosure directly places the control device on the pre-molded chip, which is formed by encapsulating the transistor in the first encapsulant and the patterned circuit layer, and thereby completes the circuit connection. Since the circuit system in the power device for rectifier of the disclosure does not require additional wire bonding, a circuit system having a low parasitic effect is achieved. Also, due to the low resistance of the transistor then a reduced VF is obtained, and thus the efficiency of the power device for rectifier is improved. In an embodiment where the control device is not required, the overall encapsulating reliability may be increased by first making the transistor into a pre-molded chip and then the pre-molded chip being electrically connected to the two terminals.
To make the aforementioned more comprehensible, several embodiments accompanied with drawings are described in detail as follows.
The accompanying drawings are included to provide a further understanding of the disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.
A description accompanied with drawings is provided in the following to comprehensively explain exemplary embodiments of the disclosure. However, it is noted that the disclosure may still be implemented according to many other different forms and should not be construed as limited to the embodiments described hereinafter. For clarity of the drawings, the sizes and thicknesses of each region, part and layer may not be illustrated according to practical scaling. For ease of understanding, the same elements in the following description will be designated the same reference numerals.
Referring to
In this embodiment, the circuit system 300 includes a pre-molded chip 310 and a control device 320. As shown in
For example, the first terminal 100, the second terminal 200 and the control device 320 are respectively electrically connected to the first electrode 3121, the second electrode 3122 and the third electrode 3123 of the transistor 312.
In another embodiment, the pre-molded chip 310 may further include a patterned circuit layer 314 connected to the transistor 312. The patterned circuit layer 314 may be electrically connected to at least one of the first electrode 3121, the second electrode 3122 and the third electrode 3123 of the transistor 312. The first encapsulant 316 encapsulates the patterned circuit layer 314 and a part of the patterned circuit layer 314 is exposed. For example, the patterned circuit layer 314 is electrically connected to the first electrode 3121 and the third electrode 3123, and the first terminal 100 and the control device 320 are respectively electrically connected to the first electrode 3121 and the third electrode 3123 via the exposed part of the patterned circuit layer 314. In this embodiment, the second electrode 3122 is exposed from the pre-molded chip 310 encapsulated by the first encapsulant 316, and the exposed second electrode 3122 is electrically connected to the second terminal 200.
In this embodiment, the transistor 312 is, for example, a field effect transistor controlled by voltage or current. In an embodiment, the transistor 312 is, for example, a MOSFET, an insulated gate bipolar transistor or a gallium nitride transistor. For example, when the transistor 312 is a MOSFET, the source, drain and gate of the MOSFET are the first electrode 3121, the second electrode 3122, and the third electrode 3123 of the transistor 312, respectively. The pads of the gate and the source of the MOSFET are on the same side facing toward the first terminal 100, the pad of the drain is on the other side facing toward the second terminal 200, and the second terminal 200 is electrically connected to the MOSFET via the pad of the drain. Since the MOSFET has a low resistance during turn-on, a lower turn on voltage (for example, a VF less than 0.5V) may be achieved, and the efficiency of the power device 10 is thereby improved. Further, the control device 320 directly contacts the patterned circuit layer 314 and is electrically connected to the third electrode 3123 of the transistor 312 via the patterned circuit layer 314; therefore traditional problems of high resistance and poor reliability caused by wire bonding are eliminated, and the integrity of the circuit system 300 is thereby improved.
In addition, the power device 10 may further include a capacitor 330, a conductive spacer 340 and so on, and a bonding material 350 (such as a solder) may be disposed between the first terminal 100 and the conductive spacer 340 so as to electrically connect the first terminal 100 and the transistor 312 in the pre-molded chip 310. As such, the inflowing alternating current is rectified to a direct current by the circuit system 300 having a rectifying function, and then the direct current is output from the power device 10.
In this embodiment, the second terminal 200 is, for example, a base electrode having a groove 200a, and the shape of the second terminal 200 is, for example, a circle, a square or a hexagon, but the disclosure is not limited thereto. In fact, the second terminal 200 may adopt different shapes or forms according to the product design requirements, for example, not having a groove, or further including a raised base (not illustrated) on the surface for placing the circuit system 300. In this embodiment, a material of the second terminal 200 includes aluminum, copper or an alloy of the foregoing metals (such as an aluminum alloy), preferably copper or aluminum. If the material of the second terminal 200 is aluminum, it may have a good thermal conductivity, a good electric conductivity and a large heat capacity. In addition, as shown in
In this embodiment, the first terminal 100 is, for example, an electrode including a base 110 and a lead 120 connected to the base 110. In this embodiment, the base 110 of the first terminal 100 is electrically connected to the lead 120, and the first terminal 100 is connected to the external circuit by the lead 120. As shown in
Next, a manufacturing process of the power device 10 will be briefly described, but the power device of the disclosure is not limited to the following process.
First, a transistor 312 is provided, and vias (not illustrated) and a patterned circuit layer 314 are formed on the transistor 312. In this embodiment, the vias may be formed on the pads of the source and gate of the transistor 312, and then the patterned circuit layer 314 may be formed on the vias, but the disclosure is not limited thereto. Then, the first encapsulant 316 encapsulates the transistor 312, the vias and the patterned circuit layer 314 by a molding process, for example. At this point, the process of manufacturing the pre-molded chip 310 is generally completed. In addition, the first encapsulant 316 exposes the patterned circuit layer 314 for the subsequent electrical connections. In this embodiment, a material of the first encapsulant 316 may include, for example, an epoxy resin, a silicone resin, a biphenyl resin, an unsaturated polyester or a ceramic material. A material of the vias and patterned circuit layer 314 is, for example, copper or other suitable metal.
Next, a control device 320, a capacitor 330 and a conductive spacer 340 are mounted on the patterned circuit layer 314. The control device 320 is electrically connected to the transistor 312 via the patterned circuit layer 314 so as to provide a drive current to control whether the transistor 312 is turned on or off. The capacitor 330 may be respectively electrically connected to the control device 320 and the transistor 312 via the patterned circuit layer 314. The conductive spacer 340 is located between the pre-molded chip 310 and the first terminal 100 so as to electrically connect the pre-molded chip 310 and the first terminal 100, and the conductive spacer 340 also has an effect of heat dissipation. Next, by method such as the molding process, a second encapsulant 360 is formed between the pre-molded chip 310 and the first terminal 100 so as to package elements such as the pre-molded chip 310, the control device 320, the capacitor 330 and the conductive spacer 340. At this point, the manufacturing of the circuit system 300 is generally completed. In this embodiment, the second encapsulant 360 exposes a part of a surface of the conductive spacer 340 for the subsequent electrical connections. In another embodiment, a layer of a bonding material 350 may be formed between the second encapsulant 360 and the first terminal 100, and the second encapsulant 360 exposes a surface of the bonding material 350 for subsequent electrical connection. In this embodiment, a material of the second encapsulant 360 may include, for example, an epoxy resin, a silicone resin, a biphenyl resin, an unsaturated polyester, or a ceramic material. A material of the bonding material 350 is, for example, lead-tin, tin-silver, or sintered silver solder, but the disclosure is not limited thereto.
Then, the circuit system 300 is disposed on the second terminal 200 such that the second terminal 200 is electrically connected to the transistor 312 in the circuit system 300; that is, an electrode of the transistor 312 is bonded to the second terminal 200, and then the first terminal 100 is disposed on the circuit system 300. Also, the transistor 312 in the circuit system 300 is electrically connected to the first terminal 100 via the exposed part of the conductive spacer 340 or via the bonding material 350. In other embodiments, another bonding material (not illustrated) may be optionally formed on a bottom surface of the groove 200a of the second terminal 200 and electrically connected to the second terminal 200 and the transistor 312 in the circuit system 300 via said bonding material (for example, a solder). In
In addition, in
Referring to both
Referring to
In this embodiment, a first terminal 100″ and the second terminal 200 are electrically connected to a transistor 312″. For example, the first terminal 100″ and the second terminal 200 are respectively electrically connected to a first electrode 3121″ and a second electrode 3122″ of the transistor 312″. In other words, a base 110″ of the first terminal 100″ substantially contacts the exposed first electrode 3121″ directly or contacts the exposed first electrode 3121″ via the bonding material 350. As such, the power device 30 having a simplified manufacturing process is obtained thereby.
In another embodiment, the pre-molded chip 310 may further include a patterned circuit layer 314 electrically connected to the first electrode 3121″. The first terminal 100″ is electrically connected to the first electrode 3121″ via the patterned circuit layer 314 exposed from the first encapsulant 316. In other words, a base 110″ of the first terminal 100″ substantially contacts the exposed patterned circuit layer 314 directly or contacts the exposed patterned circuit layer 314 via the bonding material 350. As such, the power device 30 having a simplified manufacturing process is obtained thereby.
In the disclosure, the power device 10, the power device 20 and the power device 30 as described above may be applied to a rectifier device of a vehicle generator and thereby improves the efficiency of the same.
In sum of the above, in the power device for rectifier of the disclosure, the circuit system directly connects the control device via a pre-molded chip, such that a circuit system with a low parasitic effect and low conductive resistance may be obtained and the VF of the power device may decrease thereby. As such, it can significantly reduce the power conversion loss, and thus the efficiency of the power device for rectifier can be improved.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments without departing from the scope or spirit of the disclosure. In view of the foregoing, it is intended that the disclosure covers modifications and variations provided that they fall within the scope of the following claims and their equivalents.
Number | Date | Country | Kind |
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107121274 | Jun 2018 | TW | national |