Two-Stage Power Module Voltage Conversion for Data Center Efficiency
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Solution Overview
Problem
Conventional power modules in data centers face challenges in achieving high efficiency and small volume due to high trace resistance and the unsuitability of 12V-buck converters for high-integration servers, leading to increased power loss and reduced efficiency.
Innovation Solution
A power module design featuring a first-stage and second-stage power conversion circuit on a single circuit board, where the first-stage converts a high input voltage into a transition voltage, and the second-stage converts this into a driving voltage for loads, with a shorter transmission path and optimized voltage levels to reduce power loss and enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a 12V-buck converter is used for power conversion, then the power module can be integrated on the main board, but the voltage difference between input and output is very large leading to high power loss and low efficiency
Solution Approach 1:
The power conversion process is divided into two stages: a first-stage power conversion circuit that converts the input voltage to an intermediate voltage, and a second-stage power conversion circuit that converts the intermediate voltage to the output voltage. This segmentation reduces the voltage difference in each stage, thereby reducing power loss while maintaining integration on the main board.
2Loss of energy
If the voltage of the bus bar is increased to reduce power loss, then the power transmission efficiency improves, but the current requirement decreases leading to larger trace resistance issues on the main board
Solution Approach 1:
The system changes the voltage parameter from the conventional 12V to a higher voltage (such as 48V or higher) for power transmission through the bus bar. This parameter change reduces the current required for the same power transmission, thereby reducing power loss in the bus bar while the trace resistance issue is managed through the two-stage conversion architecture.
3Length of stationary object
If the POL conversion module is placed close to the load, then the transmission path is shortened, but the large voltage difference requires a larger converter volume reducing integration efficiency
Solution Approach 1:
The power conversion function is segmented into two stages, with each stage handling a smaller voltage conversion ratio. This allows the use of smaller, more efficient converter components that can be placed closer to the load, reducing the transmission path length while maintaining a compact form factor suitable for high-integration servers.
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
This design reduces power loss and increases efficiency by minimizing the voltage difference across the second-stage power conversion circuit, allowing for higher frequency operation and smaller volume, while maintaining efficient power delivery to data processing chips.
Implementation Method 1
an input terminal of the first-stage power conversion circuit receives a first input voltage. The first input voltage is converted into a transition voltage by the first-stage power conversion circuit
Implementation Method 2
An input terminal of the second-stage power conversion circuit is electrically connected with the output terminal of the first-stage power conversion circuit to receive the transition voltage. The transition voltage is converted into a driving voltage by the second-stage power conversion circuit
Data Source
AI summary
A power module includes a circuit board and a load group. The load group is installed on the circuit board. The load group includes a first-stage power conversion circuit, a second-stage power conversion circuit and plural loads. The first-stage power conversion circuit converts an input voltage into a transition voltage. The second-stage power conversion circuit converts the transition voltage into a driving voltage. A rated value of the first input voltage is higher than twice a rated value of the transition voltage. A rated value of the driving voltage is lower than a half of the rated value of the transition voltage. The distance between the input terminal of the second-stage power conversion circuit and the output terminal of the first-stage power conversion circuit is smaller than the distance between the input terminal of the first-stage power conversion circuit and each edge of the circuit board.