Integrated TLVR Power Module With Embedded Windings for Fast Transients
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Solution Overview
Problem
Existing trans-inductor voltage regulators (TLVRs) face challenges in improving their design to meet the demands of small-size power supply apparatus and increasing performance requirements in high-performance computing systems, particularly in data centers and artificial intelligence applications, where rapid load changes and high power density are common.
Innovation Solution
A power module design comprising a device layer with power dies and an inductor assembly, featuring a magnetic core and multiple windings configured as transformers, which are embedded within the magnetic core and connected in specific magnetic and electrical configurations to enhance performance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If trans-inductors are connected in series in a multiphase TLVR, then transient response speed is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple trans-inductors into a single integrated magnetic core structure with multiple windings. The first and second trans-inductors share a common magnetic core, and their secondary windings are connected in series to form the output. This merging approach maintains the series connection benefit for transient response while reducing the number of separate components, thereby lowering device complexity.
Solution Approach 2:
The magnetic core serves multiple functions simultaneously: it provides magnetic coupling for both the first and second trans-inductors, acts as a shared inductive element, and enables series connection of secondary windings. This multi-functionality allows the structure to achieve fast transient response without proportionally increasing complexity, as one core performs the work of multiple separate components.
2Power
If power density is increased to meet performance demands, then efficiency is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent transitions from planar winding arrangements to a three-dimensional magnetic core structure with windings embedded in multiple layers and orientations. The first and second primary windings are positioned in different spatial regions of the magnetic core, and secondary windings are wound in series through multiple turns. This dimensional expansion increases power density while distributing heat generation across a larger volume, improving heat dissipation.
Solution Approach 2:
The patent implements nested windings where secondary windings are positioned inside or around primary windings within the magnetic core structure. The first secondary winding and second secondary winding are nested in series configuration, allowing compact arrangement that increases power density while the internal structure provides thermal pathways for heat dissipation.
3Area of stationary object
If physical footprint is reduced, then integration is improved, but noise immunity deteriorates
Solution Approach 1:
The patent places secondary windings inside or around primary windings in a nested configuration within the magnetic core. This nesting achieves compact footprint by utilizing the same spatial volume for multiple inductive functions. The magnetic core provides shielding that contains electromagnetic fields, and the series connection of secondary windings creates differential signaling that rejects common-mode noise, maintaining noise immunity despite reduced footprint.
Solution Approach 2:
The patent uses a composite magnetic core structure that combines magnetic materials with specific permeability characteristics to enhance magnetic coupling while containing electromagnetic interference. The core material composition is optimized to provide both high inductance in a small volume and electromagnetic shielding to protect against noise, thus maintaining noise immunity while reducing physical footprint.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides improved heat dissipation, increased power density, and better noise immunity, enabling faster transient response and higher efficiency in TLVRs, suitable for powering high-performance processors and accelerators.
Implementation Method 1
The third winding and the first winding are magnetically coupled through at least partial of the magnetic core to form a first transformer, the fourth winding and the second winding are magnetically coupled through at least partial of the magnetic core to form a second transformer
Data Source
AI summary
A power module comprises a device layer and an inductor assembly. The device layer has a first surface, an opposite second surface, and two pairs of switches. The inductor assembly, whose second surface attaches to the device layer’s first surface, has a magnetic core, a first winding, a second winding, a third winding, and a fourth winding. These windings are at least partially embedded in the magnetic core and expose ends on the second surface of the inductor assembly. The first and third windings and the magnetic core form a first transformer, and the second and fourth windings and the magnetic core form a second transformer. The third and fourth windings are electrically connected in series. The first and second windings each have a horizontal section parallel to the inductor assembly’s first surface, while the third and fourth windings are under these horizontal sections.