Stacked Power Converter Layout With Interposer and Metal Strips
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Solution Overview
Problem
There is a need for a solution that improves the space layout of stacked power converters while keeping the manufacturing process simple and costs low, as existing technologies face challenges in miniaturization and cost-effectiveness.
Innovation Solution
The solution involves a stacked power converter assembly comprising an interposer, integrated circuits, passive electrical components, and current-carrying metal strips. The integrated circuits and passive components are stacked, with the current-carrying metal strips connecting them to the interposer, allowing for efficient power conversion and reduced surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If components are arranged side-by-side in conventional layout, then manufacturing is simple, but surface area is large
Solution Approach 1:
The patent transitions from a 2D side-by-side component layout to a 3D stacked architecture. Passive electrical components are positioned vertically above active components on the interposer, utilizing the vertical dimension to reduce the horizontal footprint of the power converter assembly while maintaining all necessary electrical connections.
Solution Approach 2:
The patent implements a nested arrangement where passive electrical components (such as inductors and capacitors) are stacked directly above active components (such as power switches and control circuits) on the interposer. This nesting approach allows components to be vertically integrated, with upper components positioned over lower components, thereby minimizing the overall surface area occupied by the assembly.
2Area of moving object
If components are stacked vertically to reduce surface area, then space efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent divides the power converter into distinct functional segments or modules stacked on the interposer: active components (power switches, control circuits) in lower layers and passive components (inductors, capacitors) in upper layers. This segmentation allows each layer to be independently designed, manufactured, and tested before final assembly, simplifying the overall manufacturing process despite the 3D architecture.
Solution Approach 2:
The interposer serves multiple functions simultaneously: it provides mechanical support for all components, establishes electrical connections between stacked components through its conductive structures, provides thermal management pathways, and enables the vertical integration of diverse component types. This multi-functionality reduces the need for additional specialized structures, simplifying manufacturing.
3Area of moving object
If passive components are stacked on active components, then surface area is reduced, but current carrying capacity may be compromised
Solution Approach 1:
The patent introduces the interposer as an intermediary structure between active and passive components. The interposer contains dedicated current-carrying conductors and vias that provide low-inductance, high-current pathways connecting the power switches in the active layer to the inductors and capacitors in the passive layer, ensuring adequate current carrying capacity is maintained despite the vertical stacking arrangement.
Solution Approach 2:
The interposer replicates or mirrors the electrical connection topology of conventional 2D layouts in its 3D structure. By copying the essential current pathways and connection patterns from traditional layouts into the vertical architecture through carefully designed conductor traces and vias, the patent maintains equivalent current carrying capacity while achieving compact stacking.
Data Source
AI summary
The present disclosure relates to a stacked power converter assembly comprising: an interposer. one or more integrated circuits, such as power management integrated circuits. arranged on top of the interposer: one or more passive electrical components stacked on top of the one or more integrated circuits and one or more current-carrying metal strips arranged and connected between the one or more passive electrical components and the interposer, wherein the one or more integrated circuits and the one or more passive electrical components are configured to perform a power conversion of an input voltage and/or current to an output voltage and/or current. It also discloses a method of assembling a stacked power converter comprising the steps of: providing an interposer: placing one or more integrated circuits on the interposer: placing one or more current-carrying metal strips on the interposer: and placing one or more passive electrical components on the current-carrying metal strips.