Vertically packaged switched-mode power converter

Abstract

A vertically packaged cellular power converter solves the problems associated with conventional designs and paves the way for a cellular circuit architecture with ultra-low interconnect resistance and inductance. The vertical packaging results in a power flow in the vertical direction (from the bottom to the top) with very short internal interconnects, thereby minimizing the associated conduction losses and permitting high conversion efficiency at high currents. The cellular architecture is ideally suited for generating multiple supply voltages.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention relates to power converters and more specifically to a packaging architecture that provides for vertical power flow that is effective for providing lower supply voltages, dynamic voltage scaling, multiple supply voltages, and fast transient response and tight regulation. [0003] 2. Description of the Related Art [0004] Power converters are key components in many military and commercial systems and they often govern size and performance. Power density, efficiency and reliability are key characteristics used to evaluate the characteristics of power converters. Transformers and inductors used within these power converters may be large and bulky and often limit their efficiency, power density and reliability. These deficiencies can be improved by using a high-frequency “switch-mode” architecture instead of a traditional low frequency transformer and by replacing conventional core-and-wire designs with “pla...

AI Technical Summary

Benefits of technology

"The present invention provides a package design for a power converter that addresses the need for multiple, low supply voltages with tight regulation and fast transient responses. The vertical package design incorporates a magnetic core and winding arrangement that allows power to flow vertically from an input module to an output module. This design reduces losses and parasitics, and the use of a matrix integrated magnetics (MIM) core creates a cellular structure that can provide multiple output voltages and / or interleaving to provide output voltages with very low ripple and faster transient response. The MIM core can be positioned in different ways, such as through holes in a PCB or by extending laterally outside the core window and then turned vertically. The windings are terminated on winding pads on the input and output modules. Overall, this design provides efficient and effective power conversion for various applications."

Problems solved by technology

Transformers and inductors used within these power converters may be large and bulky and often limit their efficiency, power density and reliability.

While each individual requirement represents a challenge for the power converter design and packaging, it is the combination of them all together that is pushing the existing power conversion technology to its limit.

The conventional horizontal package has fundamental limitations that will render it ineffective for these developing applications, including a) inherently low efficiency, especially at sub-1V output, due to the long internal interconnects and the associated high conduction losses, b) a difficult 1-D interface with the load, c) inability to supply tightly regulated multiple outputs, and (d) switching frequency limitation due to the inductive and capacitive parasitics inherent in long interconnects.

The needs for coordination among multiple supply voltages, such as sequencing, also makes it difficult to use multiple, individually controlled single-output converters.

In addition, conventional control design focuses on constant output regulation with steady-state load, which cannot meet the future needs for dynamic voltage scaling and fast transient responses.

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