Voltage converter based on fractional-turn current multiplier and single-stage vertical power supply module comprising the same

Abstract

The utility model discloses a voltage transformer based on fractional turn current multiplier, multiple power module can staggered parallel operation, cooperate with multi -phase digital controller can realize voltage regulation, phase -to -phase current sharing, temperature monitoring, phase cutout function, wherein phase cutout function is favorable to improve light -duty efficiency. In order to reduce the volume of core assembly and improve the performance of converter, the inductance magnetic core is multiplexed as a part of transformer, and a new transformer and inductance magnetic integrated scheme based on fractional turn current multiplier topology is proposed. The utility model further puts forward single -stage vertical power supply module of voltage transformer based on fractional turn current multiplier, designs four -phase integrated vertical inductance, integrates four -phase output inductance into a metal powder core, greatly improves voltage regulation module current density through vertical structure design, and compact structure makes module overall height very small.

Description

Technical Field

[0001] This utility model relates to the field of vertical power supply for high-performance microprocessors, specifically to a voltage converter based on a fractional-turn current multiplier and a single-stage vertical power supply module containing the same. Background Technology

[0002] The power consumption of modern high-performance microprocessors has increased dramatically. In the traditional horizontal power supply mode, the "last inch" power supply network (PDN), consisting of the motherboard power layer and the interconnection within the processor socket, has become a key bottleneck restricting processor performance and overall system energy efficiency. To address the ultra-high current demands of processors, vertical power supply (VPD) places the current multiplier module directly below the processor, further reducing PDN impedance by 10 times compared to horizontal power supply (LPD). Furthermore, vertical power supply technology effectively reduces the impedance of the mid-frequency power supply network, mitigating the so-called "secondary voltage sag" phenomenon. Simultaneously, its sampling point is closer to the load, which helps improve the system's dynamic response capabilities.

[0003] Power supply for power ducting (POL) systems typically employs a two-stage structure. The front stage is usually a fixed-ratio converter, located on the front of the substrate, while the rear stage is a multiphase Buck converter or a more integrated integrated transformer (IVR). For IVR applications, the intermediate bus voltage is lower, typically 3.3V or 1.8V. The two-stage structure makes it difficult to achieve high power density due to the presence of inter-stage decoupling capacitors, and the series connection of the two stages also limits its efficiency. Furthermore, the placement of the front-stage intermediate bus converter on the front of the substrate occupies substrate space. Especially for IVR applications, where the intermediate bus converter has a lower voltage and higher current, it typically needs to be placed very close to the processor, further reducing substrate space.

[0004] Single-stage architectures can directly convert the 48V bus voltage to the GPU operating voltage, with relatively low 48V input current, low losses, and a smaller PCB layer footprint. However, due to the high voltage conversion, single-stage structures typically struggle to achieve high current densities. For example, the Mini-LEGO CPU voltage regulator disclosed in "Mini-LEGO CPU Voltage Regulator" by Y. Elasser et al., published in IEEE Transactions on Power Electronics, Volume 39, Issue 3, employs a four-phase vertically coupled inductor design, significantly reducing current ripple while maintaining sufficient saturation margin, and minimizing height.

[0005] The paper "1500A / 48V to 1V Switching Bus Converter for Next-Generation Ultra-High-Power Processors," published in *IEEE Transactions on Power Electronics*, Volume 39, Issue 9, authored by Y. Zhu, J. Zou, and RCN Pilawa-Podgurski, proposes a single-stage hybrid switched-capacitor (SC) voltage regulator scheme for processor vertical power supply (VPD). Its coupling inductor is specifically designed for vertical power supply, with the winding serving as both the coupling inductor component and the connection between the switching buck converter (SBC) and the processor motherboard. An ultra-thin, high-density switching buck converter (SBC) implementation is demonstrated, achieving high-frequency switching via gallium nitride field-effect transistors and employing an advanced recessed coupling inductor packaging structure to support vertical current transfer. These designs typically have current densities <0.5A / mm², severely limiting the application of single-stage structures. Utility Model Content

[0006] The technical problem to be solved by this utility model is to provide a voltage converter based on a fractional turns current multiplier with high efficiency and ultra-high power density.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: a voltage converter based on a fractional-turn current multiplier, comprising a primary-side input component and two secondary-side output components symmetrically arranged on both sides of the primary-side input component; characterized in that: the primary-side input component includes a first input capacitor and a second input capacitor connected in series between the voltage input terminal and the ground terminal; a first inverter switch and a second inverter switch are connected in series and then respectively connected to the right ends of the first input capacitor and the second input capacitor; a third inverter switch and a fourth inverter switch are connected in series and then respectively connected to the left ends of the first input capacitor and the second input capacitor;

[0008] The first primary winding of the first transformer is connected between the first inverter switch and the second inverter switch, and the other end is connected between the first input capacitor and the second input capacitor; the second primary winding of the second transformer is connected between the first input capacitor and the second input capacitor, and the other end is connected between the third inverter switch and the fourth inverter switch.

[0009] The secondary output component includes a secondary output winding coupled to a first primary winding or a second primary winding. The secondary output winding is divided into secondary winding A and secondary winding B. Secondary winding A and secondary winding B are combined to form a single loop.

[0010] The same-name terminal of secondary winding A is connected to the first rectifier switch and then to the ground terminal; the opposite-name terminal of secondary winding A is connected to the second rectifier switch and then to the ground terminal; one end of the first output inductor is connected to the same-name terminal of secondary winding A, and the other end is connected to the second output inductor; the other end of the second output inductor is connected to the opposite-name terminal of secondary winding A.

[0011] After the first secondary side capacitor and the second secondary side capacitor are connected, one end is connected to the end of the first rectifier switch near the ground terminal, and the other end is connected to the end of the second rectifier switch near the ground terminal; the connection between the first output inductor and the second output inductor and the connection between the first secondary side capacitor and the second secondary side capacitor are connected through the output wire, and the extension of the output wire is connected to the output port.

[0012] The same-name terminal of secondary winding B is connected to the ground terminal after being connected to the third rectifier switch, and the opposite-name terminal of secondary winding B is connected to the ground terminal after being connected to the fourth rectifier switch; one end of the third output inductor is connected to the same-name terminal of secondary winding B, and the other end is connected to the fourth output inductor, and the other end of the fourth output inductor is connected to the opposite-name terminal of secondary winding B.

[0013] After the third and fourth auxiliary side capacitors are connected, one end is connected to the end of the third rectifier switch near the ground terminal, and the other end is connected to the end of the fourth rectifier switch near the ground terminal; the connection between the third and fourth output inductors and the connection between the third and fourth auxiliary side capacitors are connected through the output wire, and the extension of the output wire is connected to the output port.

[0014] The first and third output inductors are in phase, and the second and fourth output inductors are in phase, with a phase difference of 180°.

[0015] As a preferred embodiment, a secondary output component is included; the primary input component includes a first input capacitor and a second input capacitor connected in series between the voltage input terminal and the ground terminal; a first inverter switch and a second inverter switch are connected in series and then connected to the right ends of the first input capacitor and the second input capacitor respectively; the same-name terminal of the first primary winding of the first transformer is connected between the first inverter switch and the second inverter switch, and the other end is connected between the first input capacitor and the second input capacitor.

[0016] As another preferred solution, two secondary output components are symmetrically arranged on both sides of the primary input component;

[0017] The primary-side input component includes a first input capacitor and a second input capacitor connected in series between the voltage input terminal and the ground terminal. A first inverter switch and a second inverter switch are connected in series and then connected to the right ends of the first input capacitor and the second input capacitor, respectively. A third inverter switch and a fourth inverter switch are connected in series and then connected to the left ends of the first input capacitor and the second input capacitor, respectively.

[0018] The first primary winding of the first transformer is connected between the first inverter switch and the second inverter switch, and the other end is connected between the first input capacitor and the second input capacitor; the second primary winding of the second transformer is connected between the first input capacitor and the second input capacitor, and the other end is connected between the third inverter switch and the fourth inverter switch.

[0019] As a preferred embodiment, the core assembly of the transformer includes a metal powder core and a central core disposed on the metal powder core. The coils of the first output inductor, second output inductor, third output inductor and fourth output inductor of the secondary output assembly are distributed in the metal powder core of the corresponding transformer and reuse the core assembly with the transformer.

[0020] As a preferred embodiment, the central magnetic core of the transformer is made of a magnetic material with high permeability and low magnetic loss; the metal powder core is made of a magnetic material with low permeability and high saturation magnetic flux density.

[0021] As a preferred embodiment, the first output inductor and the second output inductor are coupled in opposite directions; the third output inductor and the fourth output inductor are coupled in opposite directions.

[0022] As a preferred embodiment, the first output inductor and the fourth output inductor are coupled in opposite directions; the second output inductor and the third output inductor are coupled in opposite directions.

[0023] The technical problem to be solved by this utility model is to provide a single-stage vertical power supply module including the above-mentioned voltage converter based on fractional-turn current multiplier.

[0024] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: a single-stage vertical power supply module including the above-mentioned voltage converter based on fractional-turn current multiplier, including a first PCB board mounted on the motherboard, a first secondary side capacitor, a second secondary side capacitor, a third secondary side capacitor and a fourth secondary side capacitor mounted on the first PCB board, and the transformer mounted on the first PCB board; a second PCB board is mounted on the transformer;

[0025] The first inverter switch, the second inverter switch, the third inverter switch, the fourth inverter switch, the first input capacitor and the second input capacitor, the first rectifier switch, the second rectifier switch, the third rectifier switch and the fourth rectifier switch are disposed on the second PCB board;

[0026] The metal powder core is disposed on the first PCB board. The central magnetic core includes a core column and two side magnetic columns disposed on both sides of the core column. A magnetic base upper panel is mounted above the core column and the two side magnetic columns. The second PCB board is provided with several receiving holes that respectively avoid the core column and the two side magnetic columns. The corresponding first primary winding or second primary winding bypasses the corresponding core column. A secondary output winding also bypasses the core column.

[0027] The coils of the first output inductor, second output inductor, third output inductor, and fourth output inductor of the secondary output component of the transformer all pass through a metal powder core;

[0028] The grounding terminal, input terminal, and output terminal are all located on the first PCB board.

[0029] The beneficial effects of this utility model are:

[0030] This utility model adopts a modular design concept, and multiple power modules can work in parallel with each other. With the help of a multi-phase digital controller, it can realize functions such as voltage regulation, phase current sharing, temperature monitoring, and phase cut-off. The phase cut-off function is beneficial to improve light load efficiency.

[0031] To reduce the size of the magnetic core assembly while improving the performance of the converter, a novel transformer and inductor magnetic integration scheme based on fractional-turn current multiplier topology is proposed, which reuses the inductor core as part of the transformer.

[0032] Based on the different operating characteristics of transformers and inductors in current multiplier topologies, a design scheme based on different magnetic materials is proposed, in which the transformer uses ferrite material and the inductor uses metal powder core material.

[0033] This invention proposes a 48V single-stage vertical power supply solution to the load point based on a fractional-turn current multiplier topology. A four-phase integrated vertical inductor is designed, integrating the four output inductors into a single metal powder core. Simultaneously, the grounding circuit is integrated into the inductor core using a copper-iron co-firing method, eliminating connection terminals. In the single-stage vertical power supply module based on the fractional-turn current multiplier voltage converter, the transformer and inductor are designed independently. The current direction is as follows: transformer current flows horizontally through the planar PCB windings, while inductor current flows vertically. This vertical structure design significantly improves the current density of the voltage regulator module (VRM), and the compact structure results in a very small overall module height.

[0034] By placing the output capacitor on the first PCB board, the power module can be directly mounted on the back of the GPU, which helps reduce PDN impedance and improve system efficiency. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the circuit structure of a voltage converter.

[0036] Figure 2 This is a diagram showing the three operating states of the voltage converter.

[0037] Figure 3 This is a structural diagram of a single-stage vertical power supply module.

[0038] Figure 4 This is a schematic diagram of a transformer and inductor core reuse structure.

[0039] Figure 5 (a) is a schematic diagram of the direction of the primary winding current and the corresponding direction of the excitation magnetic field.

[0040] Figure 5 (b) is a schematic diagram of the secondary winding and magnetic field direction when the secondary output winding is divided into upper and lower sections;

[0041] Figure 5 (c) is a schematic diagram of the secondary winding and magnetic field direction when the secondary output winding is split into left and right sides.

[0042] Figure 6 This is the inductance matrix diagram for Maxwell simulation.

[0043] Figure 7 Flux variation diagram for different secondary output winding configurations.

[0044] Figure 8 This is a magnetic flux density distribution diagram when Iphase = 50A.

[0045] Figure 9 : This is a diagram showing the distribution of magnetic field directions.

[0046] Figure 10 This is a schematic diagram of the magnetic flux density distribution on the upper panel of the magnetic substrate.

[0047] Figure 11 : Schematic diagram of the component distribution of a single-stage vertical power supply module.

[0048] Figure 12 These are three-dimensional structural diagrams of a single-stage vertical power supply module from two different perspectives.

[0049] Figure 13 This is a schematic diagram of other design structures for a four-phase integrated inductor.

[0050] In the diagram: 1 Packaging substrate, 2 Processor, 3 Motherboard, 4 First PCB board, 51 Magnetic base top panel, 52 Magnetic core center column, 53 Side magnetic column, 6 Second PCB board. Detailed Implementation

[0051] The specific implementation scheme of this utility model will now be described in detail with reference to the accompanying drawings.

[0052] like Figure 1-3 As shown, a voltage converter based on a fractional-turn current multiplier includes a primary-side input component and two secondary-side output components symmetrically arranged on both sides of the primary-side input component. The primary-side input component includes a first input capacitor C1 and a second input capacitor C2 connected in series between the voltage input terminal Vin and the ground terminal GND. A first inverter switch Q1 and a second inverter switch Q2 are connected in series and then connected to the right ends of the first input capacitor C1 and the second input capacitor C2, respectively. A third inverter switch Q3 and a fourth inverter switch Q4 are connected in series and then connected to the left ends of the first input capacitor C1 and the second input capacitor C2, respectively.

[0053] The first primary winding of the first transformer is connected between the first inverter switch Q1 and the second inverter switch Q2, and the other end is connected between the first input capacitor C1 and the second input capacitor C2; the second primary winding of the second transformer is connected between the first input capacitor C1 and the second input capacitor C2, and the other end is connected between the third inverter switch Q3 and the fourth inverter switch Q4.

[0054] The secondary output component includes a secondary output winding coupled to the first primary winding or the second primary winding. The secondary output winding is divided into secondary winding A and secondary winding B. Secondary winding A and secondary winding B are arranged in a loop. Each of secondary winding A and secondary winding B has 0.5 turns.

[0055] The same-name terminal of secondary winding A is connected to the ground terminal GND after being connected to the first rectifier switch QR1, and the opposite-name terminal of secondary winding A is connected to the ground terminal after being connected to the second rectifier switch QR2; one end of the first output inductor L1 is connected to the same-name terminal of secondary winding A, and the other end is connected to the second output inductor L2, and the other end of the second output inductor L2 is connected to the opposite-name terminal of secondary winding A.

[0056] The first secondary side capacitor C1' and the second secondary side capacitor C2' are connected in series. One end of the capacitor is connected to the end of the first rectifier switch QR1 near the ground terminal, and the other end is connected to the end of the second rectifier switch QR2 near the ground terminal. The connection between the first output inductor L1 and the second output inductor L2 and the connection between the first secondary side capacitor C1' and the second secondary side capacitor C2' are connected through an output wire. The extension of the output wire is connected to the output port V0.

[0057] The same-name terminal of the secondary winding B is connected to the ground terminal GND after being connected to the third rectifier switch QR3, and the opposite-name terminal of the secondary winding B is connected to the ground terminal after being connected to the fourth rectifier switch QR4; one end of the third output inductor L3 is connected to the same-name terminal of the secondary winding B, and the other end is connected to the fourth output inductor L4, and the other end of the fourth output inductor L4 is connected to the opposite-name terminal of the secondary winding B.

[0058] After the third secondary-side capacitor C3' and the fourth secondary-side capacitor C4' are connected in series, one end is connected to one end of the third rectifier switch QR3 close to the ground terminal, and the other end is connected to one end of the fourth rectifier switch QR4 close to the ground terminal; the connecting wire between the third output inductor L3 and the fourth output inductor L4 and the connecting wire between the third secondary-side capacitor C3' and the fourth secondary-side capacitor C4' are connected via an output wire, and the extended section of the output wire is connected to the output port V0.

[0059] The first output inductor L1 and the third output inductor L3 are in phase, the second output inductor L2 and the fourth output inductor L4 are in phase, and the phase difference between the two is 180°.

[0060] The voltage converter consists of two half-bridge converters that are symmetrical left and right, which ensures the symmetry of the system and is beneficial to reducing leakage inductance. In order to increase the conversion ratio, optimize the structure and improve the power density, the secondary winding adopts a half turn, that is, 0.5 turns, so the conversion ratio of the converter is D / 4N, where D is the duty cycle of the primary-side inverter switch (0<D<0.5), and N is the number of turns of the primary winding of the transformer. When N=4 and D=0.25, the converter can realize 48V-0.75V conversion. With discrete inductors, each secondary winding is connected to two output inductors, and the entire voltage converter has a total of eight outputs.

[0061] As shown in Figure 2 , the converter has three working states:

[0062] Mode 1: the primary-side inverter switches Q1 and Q3 are conducting, Q2 and Q4 are turned off, and the transformer excitation current changes from negative to positive. The secondary-side rectifier switches QR2 and QR4 are turned on, QR1 and QR3 are turned off, the currents of the output inductors L1 and L3 increase, and the freewheeling currents of L2 and L4 decrease.

[0063] Mode 2 and Mode 4: all the inverter switches Q1, Q2, Q3 and Q4 are turned off, and the excitation current of the transformer remains unchanged. All rectifier switches are turned on, the inductors perform freewheeling, and the current decreases.

[0064] Mode 3: the primary-side inverter switches Q2 and Q4 are conducting, Q1 and Q3 are turned off, and the transformer excitation current changes from positive to negative after increasing. The secondary-side rectifier switches QR1 and QR3 are turned on, QR2 and QR4 are turned off, the currents of the output inductors L2 and L4 increase, and the freewheeling currents of L1 and L3 decrease.

[0065] As shown in Figure 3-6As shown, a single-stage vertical power supply module including a voltage converter based on a fractional-turn current multiplier as described above includes a main board 3 mounted on a package substrate 1. A first PCB board 4 is mounted on the main board 3. A first secondary side capacitor C1', a second secondary side capacitor C2', a third secondary side capacitor C3', and a fourth secondary side capacitor C4' are embedded in the first PCB board 4 (or can be directly mounted on the first PCB board 4). A first transformer and a second transformer are mounted on the first PCB board. A second PCB board is mounted on the first transformer and the second transformer.

[0066] The first inverter switch Q1, the second inverter switch Q2, the third inverter switch Q3, the fourth inverter switch Q4, the first input capacitor C1 and the second input capacitor C2, the first rectifier switch QR1, the second rectifier switch QR2, the third rectifier switch QR3, and the fourth rectifier switch QR4 are disposed on the second PCB board 6.

[0067] The magnetic core assemblies of both the first and second transformers include a metal powder core disposed on the first PCB board and a central magnetic core disposed on the corresponding metal powder core. The central magnetic core includes a magnetic core pillar 52 and two side magnetic pillars 53 distributed on both sides of the magnetic core pillar 52. A magnetic base upper panel 51 is mounted above the magnetic core pillar 52 and the two side magnetic pillars 53. The second PCB board 6 has several receiving holes that respectively avoid the magnetic core pillar 52 and the two side magnetic pillars 53. The corresponding first primary winding or second primary winding bypasses the magnetic core pillar 52. A secondary output winding also bypasses the magnetic core pillar 52.

[0068] The coils of the first output inductor L1, the second output inductor L2, the third output inductor L3, and the fourth output inductor L4 of the secondary output component of the first transformer pass through the metal powder core and are shared with the magnetic core assembly of the first transformer.

[0069] The coils of the first output inductor L1, the second output inductor L2, the third output inductor L3, and the fourth output inductor L4 of the secondary output component of the second transformer pass through the metal powder core and share the magnetic core assembly with the second transformer; the grounding terminal GND, the input terminal Vin, and the output terminal V0 are all located on the first PCB board 4.

[0070] In this design, since the transformer and output inductor cores are reused, there is coupling between the transformer's magnetizing inductance and the output inductance. The coupling situation varies depending on the configuration of the secondary winding.

[0071] Figure 5 The diagram shows the directions of the current and magnetic field in mode 1. Figure 5 (a) shows the direction of the primary winding current and the corresponding excitation magnetic field direction on the upper panel of the magnetic base and the inductor core. The transformer secondary winding is a half-turn winding, with two configuration options. Figure 5 In (b), the secondary winding is divided into upper and lower parts as shown in the diagram. Each half-turn of the secondary winding is connected to two output inductors. The direction of the induced voltage and current in the secondary winding can be obtained using Faraday's law of electromagnetic induction. Figure 3 (a) The magnetic field directions of the corresponding output inductors L1-L4 can be obtained. Observing the magnetic field directions, it can be found that the excitation inductance Lm of the transformer is positively coupled with the output inductors L1 and L3, and negatively coupled with the output inductors L2 and L4.

[0072] exist Figure 5 In (c), the secondary winding is divided into two parts as shown in the figure (located on the left and right sides of the bottom plate of the magnetic base, respectively). Similarly, it can be analyzed that the excitation inductance Lm of the transformer is reverse coupled with the output inductances L1 and L3, and forward coupled with the output inductances L2 and L4.

[0073] In addition to the coupling between the magnetizing inductor Lm and the four-phase output inductors L1-L4, the four-phase output inductors L1-L4 are also coupled to each other. The impact of inductive coupling on converter performance is analyzed below.

[0074] Firstly, from the perspective of equivalent inductance, the coupling between the magnetizing inductance Lm and the various output inductors L1-L4 can be expressed as:

[0075]

[0076] in U Lm U represents the voltage across the magnetizing inductor Lm. Lj,j＝1,2,3,4 i represents the voltage across the output inductor of phase j. Lm Indicates the excitation current, i Lj,j＝1,2,3,4 M represents the output inductor current of phase j. 0j,j＝1,2,3,4 L represents m With L j Mutual intuition between them

[0077] M ij,i＝1,2,3,4,j＝1,2,3,4,i≠j This indicates the mutual inductance between the output inductors.

[0078] Since the core assembly structure is symmetrical, the following assumptions are made:

[0079]

[0080] We can obtain:

[0081]

[0082] Define the coupling coefficient:

[0083]

[0084] Where α0 represents the magnetizing inductance L m With output inductor L o The coupling coefficients are as follows: α1 represents the total coupling coefficient between one output inductor and two adjacent output inductors, i.e., the total coupling coefficient between one output inductor and two inductors of different phases; α2 represents the coupling coefficient between one output inductor and a diagonal output inductor, i.e., the coupling coefficient between one output inductor and an inductor of the same phase. The inductor voltages in modes 1, 2, and 3 are respectively:

[0085]

[0086] Taking mode 1 as an example,

[0087]

[0088] The calculation yielded:

[0089]

[0090] It can be observed that when α0>0, i.e., the magnetizing inductance L m When forward coupled with output inductors L1 and L3, the equivalent output inductance of the first and third phases increases.

[0091] Similarly, it can be deduced that when the magnetizing inductance L... m When reverse-coupled with output inductors L2 and L4, the equivalent output inductance of the second and fourth phases increases.

[0092] A model was built in Maxwell, with ur = 60 and the gap between the upper panel of the magnetic base and the powder core inductor set to 0.02 mm. The simulation results are as follows. Figure 6 As shown, when N=4, the calculated steady-state equivalent inductance is 68.3nH. Assuming there is no coupling between Lm and Lo, the calculated steady-state equivalent inductance is 59.6nH. It can be seen that compared with non-coupling, coupling increases the steady-state inductance by 14.6%, which is beneficial to reduce inductor ripple current and reduce losses.

[0093] From the perspective of magnetic flux, since most of the AC magnetic flux of the transformer flows back through the middle part of the inductor core, i.e., the non-coupled path, we should focus on the magnetic flux situation in the middle part. Figure 7 The magnetic flux variation under different secondary winding configurations. Figure 7 The change in magnetic flux in (a) corresponds to Figure 5 (b) winding configuration, Figure 7 (b) corresponds to the change in magnetic flux Figure 5 The winding configuration in (c) can be observed Figure 7 (a) The superposition of AC magnetic flux helps reduce ripple, which in turn helps reduce the loss of the magnetic core assembly, further verifying that Figure 5 (b) Advantages of secondary winding configuration.

[0094] The simulation yielded the following magnetic flux density distributions for the transformer and inductor when the current per phase was 50A: Figure 8 As shown, it can be observed that, except for the relatively large magnetic flux density around the copper block of the inductor, the magnetic flux density in other parts is relatively small, which verifies the soft saturation characteristic of the inductor and also ensures the reliable operation of the converter.

[0095] Another issue to consider is the magnetic flux density distribution between the magnetic substrate's upper panel and the inductor's contact surface. Given the high magnetic flux density of the inductor core, could this lead to excessively high magnetic flux density at the contact surface, potentially causing saturation of the ferrite core assembly's contact surface? (Observation) Figure 5 It can be observed that the magnetic field generated by the output inductor current is horizontal, meaning the magnetic flux flows in the XY plane, while the magnetic field generated by the excitation inductor current is vertical, meaning the magnetic flux flows in the YZ plane. Figure 9 Simulations of the magnetic field direction further validated this analysis, confirming that the inductor's magnetic field and the transformer's magnetic field are decoupled. The simulation yielded the magnetic flux density distribution on the upper panel of the magnetic substrate as follows: Figure 10 As shown, it can be observed that the magnetic flux density of the upper panel of the magnetic base is low, and the contact surface does not show saturation.

[0096] Based on the above design, this solution can achieve a higher current density compared to existing technologies, where the current density of existing single-stage solutions is typically below 0.5 A / mm². 2 This solution can achieve 1.5A / mm 2 It eliminates the last inch of impedance in horizontal power supply, enabling higher efficiency.

[0097] For vertical power supply applications, the output capacitor is embedded in the first PCB board, such as... Figure 12 As shown, the voltage regulator module (VRM) can be directly mounted on the back of the high-performance microprocessor. Multiple modules can operate in parallel with interleaving. Each module requires two phases of pulse width modulation (PWM), and with a 32-phase controller, a 5000A output can be achieved. Each module also has an enable function; under light load conditions, some modules can be removed by phase switching to improve efficiency. Furthermore, since the operation and power supply of different areas are independent, phase switching can also be used to remove some modules, retaining only the parts requiring power, to improve efficiency.

[0098] Four-phase integrated inductor design expansion

[0099] For four-phase integrated inductors, besides Figure 4 Besides the design in the original design, there are many other design options to optimize characteristics such as inductance, inductance ratio, and saturation. Figure 13 The following are three different design methods. Figure 13 (a) There is basically no coupling between the four phase inductors. Figure 13(b) The first output inductor L1 and the fourth output inductor L4 are coupled in opposite directions; the second output inductor L2 and the third output inductor L3 are coupled in opposite directions. Figure 13 (c) The first output inductor L1 and the second output inductor L2 are coupled in opposite directions; the third output inductor L3 and the fourth output inductor L4 are coupled in opposite directions. By designing the structural parameters, parameters such as self-inductance and mutual inductance can be adjusted to optimize the design.

[0100] The above embodiments are merely illustrative of the principles and effects of the present invention, as well as some examples of its application, and are not intended to limit the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the inventive concept of the present invention, and these modifications and improvements are all within the protection scope of the present invention.

Claims

1. A voltage converter based on a fractional-turn current multiplier, comprising a primary-side input component and at least one secondary-side output component; characterized in that: The secondary output component includes a secondary output winding coupled to the primary winding of the corresponding transformer in the primary input component. The secondary output winding is divided into secondary winding A and secondary winding B; secondary winding A and secondary winding B are combined to form a loop. The same-name terminal of secondary winding A is connected to the first rectifier switch and then to the ground terminal; the opposite-name terminal of secondary winding A is connected to the second rectifier switch and then to the ground terminal; one end of the first output inductor is connected to the same-name terminal of secondary winding A, and the other end is connected to the second output inductor; the other end of the second output inductor is connected to the opposite-name terminal of secondary winding A. After the first secondary side capacitor and the second secondary side capacitor are connected, one end is connected to the end of the first rectifier switch near the ground terminal, and the other end is connected to the end of the second rectifier switch near the ground terminal; the connection between the first output inductor and the second output inductor and the connection between the first secondary side capacitor and the second secondary side capacitor are connected through the output wire, and the extension of the output wire is connected to the output port. The same-name terminal of secondary winding B is connected to the ground terminal after being connected to the third rectifier switch, and the opposite-name terminal of secondary winding B is connected to the ground terminal after being connected to the fourth rectifier switch; one end of the third output inductor is connected to the same-name terminal of secondary winding B, and the other end is connected to the fourth output inductor, and the other end of the fourth output inductor is connected to the opposite-name terminal of secondary winding B. After the third and fourth auxiliary side capacitors are connected, one end is connected to the end of the third rectifier switch near the ground terminal, and the other end is connected to the end of the fourth rectifier switch near the ground terminal; the connection between the third and fourth output inductors and the connection between the third and fourth auxiliary side capacitors are connected through the output wire, and the extension of the output wire is connected to the output port. The first and third output inductors are in phase, and the second and fourth output inductors are in phase, with a phase difference of 180°.

2. The voltage converter based on a fractional-turn current multiplier as described in claim 1, characterized in that: It includes a secondary output component; the primary input component includes a first input capacitor and a second input capacitor connected in series between the voltage input terminal and the ground terminal; the first inverter switch and the second inverter switch are connected in series and then connected to the right ends of the first input capacitor and the second input capacitor respectively; the same-name terminal of the first primary winding of the first transformer is connected between the first inverter switch and the second inverter switch and the other end is connected between the first input capacitor and the second input capacitor.

3. A voltage converter based on a fractional-turn current multiplier as described in claim 1, characterized in that: Includes two secondary output components symmetrically arranged on both sides of the primary input component; The primary-side input component includes a first input capacitor and a second input capacitor connected in series between the voltage input terminal and the ground terminal. A first inverter switch and a second inverter switch are connected in series and then connected to the right ends of the first input capacitor and the second input capacitor, respectively. A third inverter switch and a fourth inverter switch are connected in series and then connected to the left ends of the first input capacitor and the second input capacitor, respectively. The first primary winding of the first transformer is connected between the first inverter switch and the second inverter switch, and the other end is connected between the first input capacitor and the second input capacitor; the second primary winding of the second transformer is connected between the first input capacitor and the second input capacitor, and the other end is connected between the third inverter switch and the fourth inverter switch.

4. A voltage converter based on a fractional-turn current multiplier as described in claim 1, characterized in that: The core assembly of the transformer includes a metal powder core and a central core disposed on the metal powder core. The coils of the first output inductor, the second output inductor, the third output inductor and the fourth output inductor of the secondary output assembly are distributed in the metal powder core of the corresponding transformer and reuse the core assembly with the transformer.

5. A voltage converter based on a fractional-turn current multiplier as described in claim 4, characterized in that: The transformer's central magnetic core is made of a magnetic material with high permeability and low magnetic loss; the metal powder core is made of a magnetic material with low permeability and high saturation magnetic density.

6. A voltage converter based on a fractional-turn current multiplier as described in any one of claims 4 or 5, characterized in that: The first output inductor and the second output inductor are coupled in opposite directions; the third output inductor and the fourth output inductor are coupled in opposite directions.

7. A voltage converter based on a fractional-turn current multiplier as described in any one of claims 4 or 5, characterized in that: The first output inductor and the fourth output inductor are coupled in opposite directions; the second output inductor and the third output inductor are coupled in opposite directions.

8. A single-stage vertical power supply module comprising a voltage converter based on a fractional-turn current multiplier as described in any one of claims 4-7, comprising a first PCB board disposed on a motherboard, a first secondary side capacitor, a second secondary side capacitor, a third secondary side capacitor and a fourth secondary side capacitor disposed on the first PCB board, the transformer disposed on the first PCB board; and a second PCB board disposed on the transformer. The first inverter switch, the second inverter switch, the third inverter switch, the fourth inverter switch, the first input capacitor and the second input capacitor, the first rectifier switch, the second rectifier switch, the third rectifier switch and the fourth rectifier switch are disposed on the second PCB board; The metal powder core is disposed on the first PCB board. The central magnetic core includes a core column and two side magnetic columns disposed on both sides of the core column. A magnetic base upper panel is mounted above the core column and the two side magnetic columns. The second PCB board is provided with several receiving holes that respectively avoid the core column and the two side magnetic columns. The corresponding first primary winding or second primary winding bypasses the corresponding core column. A secondary output winding also bypasses the core column. The coils of the first output inductor, second output inductor, third output inductor, and fourth output inductor of the secondary output component of the transformer all pass through a metal powder core; The grounding terminal, input terminal, and output terminal are all located on the first PCB board.

Images