Voltage Regulator Module Power Stage With Parallel Thermal Paths
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Solution Overview
Problem
Conventional voltage regulator modules have thermal resistances above 5.2K/W, which is insufficient for high-power applications requiring lower thermal resistance.
Innovation Solution
The design incorporates a power stage package with first and second pads, where the second pad is not part of the phase current path, and uses an inductor and a metallic clip or body to create parallel thermal paths for heat dissipation, reducing thermal resistance to 2.6K/W.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional inductor-cooled power stage modules are used, then thermal resistance can be reduced to 5.2K/W, but this is still insufficient for high-power applications requiring even lower thermal resistance
Solution Approach 1:
The power stage package is segmented into multiple pads (first pad for phase current output, second pad for thermal management) to separate thermal management functions from electrical current paths. This segmentation allows dedicated thermal pathways without interfering with power delivery, enabling thermal resistance below 5.2K/W while maintaining high power handling capability.
Solution Approach 2:
A metallic clip or body is introduced as an intermediary component between the power stage package and the substrate. This metallic intermediary provides a low-thermal-resistance pathway from the second pad to the substrate, achieving thermal resistance below 5.2K/W without requiring the second pad to carry phase current, thus resolving the contradiction between thermal management and power handling.
2Temperature
If the second pad is used for thermal contact, then thermal resistance is reduced, but the pad must not carry phase current which limits electrical connection options
Solution Approach 1:
The pad structure is segmented into functionally distinct first pad (electrical current path) and second pad (thermal path only). This segmentation simplifies the design by clearly defining each pad's purpose, reducing the complexity of pad configuration while achieving both thermal management and electrical connection requirements.
Solution Approach 2:
The power stage package design incorporates universal functionality where the first pad handles both electrical and thermal aspects of phase current output, while the second pad is universally dedicated to thermal management only. This multi-functional approach simplifies the overall device complexity by establishing clear functional zones.
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 solution achieves a thermal resistance of 2.6K/W, effectively managing heat dissipation in high-power applications by utilizing parallel thermal paths through the inductor and metallic clip, enhancing cooling efficiency.
Implementation Method 1
a metallic clip attached to each of the second end of the vertical conductor, the power output terminal of the substrate, and the second pad of the power stage package
Implementation Method 2
an inductor having a vertical conductor embedded in a magnetic core
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
A voltage regulator module includes: a substrate having power input and output terminals; a power stage package mounted to the substrate and having first and second pads at a side facing away from the substrate, the power stage package configured to receive an input voltage from the power input terminal and output a phase current at the first pad; an inductor having a vertical conductor embedded in a magnetic core, the vertical conductor having a first end attached to the first pad of the power stage package and an opposite second end; and a metallic clip attached to each of the second end of the vertical conductor, the power output terminal, and the second pad of the power stage package. The second pad of the power stage package does not carry any of the phase current.