Flexible power converter architecture based on interposer and modular electronic units

• US 10,340,812 B2
• Filed: 09/13/2017
• Issued: 07/02/2019
• Est. Priority Date: 09/13/2017
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Jacobson, Boris S., Bernstein, Steven D., Lardizabal, Steven M., Adams, Jason, Laroche, Jeffrey R.
• Primary Examiner(s): Finch, III, Fred E
• Assistant Examiner(s): Jamali, Ishrat F
• Application Number:
  US15/703,455
• Publication Number:
  US 20190081567A1
• Time in Patent Office: 657 Days
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/28 Coils; Windings; Conductive connections
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 27/36 Electric or magnetic shields or screens movable for varying inductance H01F21/10
• CPC Class Codes: H01F 27/361 made of combinations of electrically conductive material and ferromagnetic material
• CPC Class Codes: H01F 27/363 made of electrically conductive material
• CPC Class Codes: H01F 27/366 made of ferromagnetic material
• CPC Class Codes: H01F 27/42 Circuits specially adapted for the purpose of modifying, or compensating for, electric characteristics of transformers, reactors, or choke coils circuits for controlling transformers, reactors or choke coils, for the purpose of obtaining a desired output H02P13/00; impedance networks H03H
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/008 Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators
• CPC Class Codes: H02M 3/335 using semiconductor devices only
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/04 by static converters

Abstract

A modular high-power converter system includes an electronic power distribution unit configured to output an analog current (AC) voltage to a power bus, and at least one Transmit or Receive Integrated Microwave Module (T/RIMM) that includes a voltage converter unit and a transmitter and receiver (T/R) unit. The voltage converter unit includes at least one analog-to-digital converter (ADC) to convert the AC voltage into a direct current (DC) voltage having a first DC voltage level. The transmitter and receiver (T/R) unit includes a modular-based DC/DC converter to convert the DC voltage into a second DC voltage having a second voltage. The modular-based DC/DC converter includes a modular power converter unit configured to generate the second DC voltage. The modular converter unit is configured to be independently interchangeable with a different modular converter unit.

Claims

1. A modular high-power converter system comprising:

an electronic power distribution unit configured to output an alternating current (AC) voltage to a power bus; and

at least one Transmit or Receive Integrated Microwave Module (T/RIMM) configured to perform at least one of signal transmission or signal reception, the T/RIMM comprising;

an electronic voltage converter unit including at least one alternating current-to-direct current converter (AC/DC) in signal communication with the power bus, the AC/DC configured to convert the AC voltage into a direct current (DC) voltage having a first DC voltage level,

at least one electronic transmitter and receiver (T/R) unit in signal communication with the output of the AC/DC, the at least one T/R unit including a modular-based direct current-to-direct current (DC/DC) converter connected to the output of the AC/DC to convert the DC voltage into a second DC voltage having a second voltage different from the first voltage level,

wherein the modular-based DC/DC converter includes a plurality of modular power converter units configured to generate the second DC voltage, each modular converter unit configured to be independently interchangeable with a different modular converter unit, each modular power converter unit configured to perform a different electronic power conversion operation with respect to one another, wherein each modular converter unit is configured to be independently removed without disconnecting the modular-based DC/DC converter.

2. The modular high-power converter system of claim 1, wherein a first individual modular power converter unit is configured to be independently interchangeable with respect to every remaining modular power converter unit.

3. The modular high-power converter system of claim 2, wherein the modular-based DC/DC converter includes an interposer substrate that supports the plurality of modular power converter units, the interposer forming an electrical routing interface among each modular power converter unit included in the plurality of modular power converter units.

4. The modular high-power converter system of claim 3, wherein the interposer includes at least one intermediate substrate layer located between an upper surface of the interposer and a lower surface of the interposer.

5. The modular high-power converter system of claim 4, wherein at least one of the modular converter units among the plurality of modular converter units is mounted on the interposer and extends through the at least one intermediate substrate layer.

6. The modular high-power converter system of claim 3, wherein the plurality of modular converter units includes at least one of a modular integrated input capacitor unit, a modular primary power switching unit, a modular transformer unit, a modular inductor unit, a modular secondary power switching unit, a modular controller and signal isolator unit, and a modular integrate output capacitor unit, a modular integrated output electromagnetic interference (EMI) filter unit, and a modular integrated sensor unit.

7. The modular high-power converter system of claim 6, wherein the modular transformer unit includes a magnetic core, primary windings, primary shields, secondary windings, and secondary shields.

8. The modular high-power converter system of claim 7, wherein the modular transformer unit is constructed as a four-winding transformer, the four-winding transformer including a magnetic core, two primary windings each having a first number of turns, and two secondary windings each having a second number of turns.

9. The modular high-power converter system of claim 7, wherein the modular transformer unit is constructed as an eight-winding transformer, the eight-winding transformer including a magnetic core, four primary windings each having a first number of turns, and four secondary windings each having a second number of turns.

10. The modular high-power converter system of claim 6, wherein the modular inductor unit includes a magnetic core and a plurality of independent inductor cells.

11. The modular high-power converter system of claim 10, wherein the modular inductor unit is dynamically reconfigured to vary an inductance in response to actively selecting a number of connected inductor cells among the plurality of independent conductor cells in real time without disconnecting the modular-based DC/DC converter.

12. The modular high-power converter system of claim 6, wherein the interposer includes a plurality of metalized layers, and the modular capacitor unit includes a plurality of individual capacitor circuits dispersed among the plurality of metalized layers.

13. The modular high-power converter system of claim 12, wherein the plurality of metalized layers includes at least one first capacitance layer, at least one second capacitance layer, and at least one shielding layer interposed between the at least one first capacitance layer and the at least one second capacitance layer, the shielding layer serving as an electric field shielding between the at least one first capacitance layer and the at least one capacitance layer second capacitor circuit.

14. An electronic transceiver/receiver (T/R) unit included in a Transmit or Receive Integrated Microwave Module (T/RIMM) installed in a modular high-power converter system, the comprising:

a power amplifier connected to an antenna to perform at least one of signal transmission or signal reception; and

a modular direct current-to-direct current (DC/DC) converter configured to convert a first DC voltage into a reduced second DC voltage that drives the power amplifier, the modular-based DC/DC converter including a plurality of modular power converter units configured to generate the second DC voltage,

wherein each modular converter unit configured to be independently interchangeable with a different modular converter unit,

each modular power converter unit configured to perform a different electronic power conversion operation with respect to one another, wherein each modular converter unit is configured to be independently removed without disconnecting the modular-based DC/DC converter.

15. The T/R unit of claim 14, wherein a first individual modular power converter unit is configured to be independently interchangeable with respect to every remaining modular power converter unit.

16. The T/R unit of claim 15, wherein the modular-based DC/DC converter includes an interposer substrate that supports the plurality of modular power converter units, the interposer forming an electrical routing interface among each modular power converter unit included in the plurality of modular power converter units.

17. The T/R unit of claim 16, wherein the interposer includes at least one intermediate substrate layer located between an upper surface of the interposer and a lower surface of the interposer, and at least one of the modular converter units among the plurality of modular converter units is mounted on the interposer and extends through the at least one intermediate substrate layer.

18. A method of assembling a plurality of modular converter units to construct a modular-based direct current-to-direct current (DC/DC) converter, the method comprising:

connecting an electronic power distribution unit configured to a power bus that is configured to receive an alternating current (AC) voltage;

connecting, to the power bus, an electronic voltage converter unit including at least one alternating current-to-direct current converter (AC/DC), the AC/DC configured to convert the AC voltage into a direct current (DC) voltage having a first DC voltage level;

connecting at least one electronic transmitter and receiver (T/R) unit with the output of the AC/DC;

forming a plurality of interchangeable modular converter units on an interposer included on the T/R unit to construct the modular-based DC/DC converter, the plurality of interchangeable modular converter units configured to convert the DC voltage into a second DC voltage having a second voltage different from the first voltage level, wherein the modular-based DC/DC converter is dynamically reconfigured in real time in response to interchanging a first modular converter unit independently with respect to remaining modular converter units without disconnecting the modular-based DC/DC converter.