Heat-sink-coupled conductor structures with integrated current sensors and eddy current mitigation

A method of making a power module conductor structure with integrated current sensor, the method comprising:

• providing a higher-current conductor structure having a main current path including an S-notch portion configured to mitigate eddy currents;
• providing a lower-current conductor structure configured for connection to a heat sink and having a main current path, wherein the higher-current conductor structure is configured to conduct a higher current level than the lower-current conductor structure;
• providing a power converter connected to the higher-current conductor structure and the lower-current conductor structure, wherein the power converter is configured to convert power between a high current in the higher-current conductor structure and a low current in the lower-current conductor structure;
• and
• providing a differential current sensor including one or more magnetic field sensing elements, wherein the differential current sensor is configured to detect current flowing in the higher-current conductor structure,
• wherein the higher-current conductor structure comprises first and second planar conductive layers and an insulator layer disposed between the first and second planar conductive layers, wherein the first planar conductive layer includes the main current path.