High current density power module

A method of manufacturing a power block of a power converter, the method comprising:

• mounting an inductor unit and a first set of components on a first side of a first substrate, the inductor unit comprising a magnetic core and a winding embedded within the magnetic core;
• encapsulating the inductor unit and the first set of components in a molding compound;
• grinding down the molding compound to a first side of the inductor unit, thereby planarizing a surface of the molding compound and exposing contact pads on the first side of the inductor unit;
• forming one or more cavities in the molding compound in regions adjacent to the inductor unit;
• and
• assembling a second substrate onto the inductor unit, the second substrate having a second set of components disposed thereon, the second set of components being received in the one or more cavities,
• wherein one or more power stage integrated circuits are disposed on one of the first substrate and the second substrate.

A power module comprising:

• a first substrate having a first side and a second side;
• one or more power stage integrated circuits disposed on the first side of the first substrate;
• a second substrate having a first side and a second side, the first side of the second substrate facing the second side of the first substrate;
• two or more inductor units disposed between the first substrate and the second substrate, each of the two or more inductor units comprising a magnetic core and a winding embedded within the magnetic core;
• a molding compound disposed between the first and second substrates and at least partially encapsulating the two or more inductor units, the molding compound having one or more cavities in regions adjacent to the two or more inductor units;
• a first set of components embedded in the molding compound;
• and
• a second set of components disposed in the one or more cavities.