3D structure design of magnetic ferrite cores using gelcasting and pressure-less sintering process

Abstract

Gelcasting is a well established process for ceramics manufacturing which recently has been proved to be successful for soft ferrites as well. This approach is particularly interesting for power electronics application in which the magnetic components (e.g. transformers and inductors) are three dimensionally integrated on the power module substrate. This paper proposes a gelcasting process adapted to make it more effective for 3D heterogeneous integration. The main novelties in this direction consist of low solid load (65wt%) and gelation without catalyst to improve casting and de-airing steps. The magnetic properties of gelcast samples are compared with commercial materials and correlated with the microstructure.

A novel manufacturing technique for integrating magnetic components windings on power module substrates

“…This approach allows to optimise locally the commutation loop and the gate driver circuit, hence reducing the parasitic inductances to reach SiC and Gan full potential. In addition to that, the physical integration of the output inductor together with the switching devices on the same substrate can give further benefits [3]. Firstly, thanks to this packaging solution the high frequency switching noises are contained at the source and do not contaminate the end user.…”