Power converter

• US 10,389,235 B2
• Filed: 05/09/2017
• Issued: 08/20/2019
• Est. Priority Date: 05/05/2011
• Status: Active Grant

• Current Assignee: pSemi Corporation (Murata Manufacturing Co Limited)
• Original Assignee: pSemi Corporation (Murata Manufacturing Co Limited)
• Inventors: Giuliano, David
• Primary Examiner(s): Berhane, Adolf D
• Assistant Examiner(s): Lee, Jye-June
• Application Number:
  US15/590,562
• Publication Number:
  US 20170244318A1
• Time in Patent Office: 833 Days
• 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 1/42 Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
• CPC Class Codes: H02M 3/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 3/07 using capacitors charged and discharged alternately by semiconductor devices with control electrode , e.g. charge pumps
• CPC Class Codes: H02M 3/077 with parallel connected charge pump stages
• CPC Class Codes: H02M 3/1582 Buck-boost converters H02M3/1584 takes precedence
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Abstract

An apparatus for power conversion includes a transformation stage for transforming a first voltage into a second voltage. The transformation stage includes a switching network, a filter, and a controller. The filter is configured to connect the transformation stage to a regulator. The controller controls the switching network.

Claims

1. An apparatus comprising switches for operating a switched-capacitor converter, said switches being configured to transition between first and second states so as to cause said switched-capacitor converter to transition between first and second switch arrangements, said apparatus further comprising a first die, and a second die, wherein said switches comprise phase switches and stack switches, wherein said first and second dies are configured according to a configuration selected from the group consisting of a first configuration and a second configuration, wherein, in said first configuration, said phase switches are on said first die and said stack switches are on said second die, and wherein, in said second configuration, a controller is on said first die and said switches are on said second die.

2. The apparatus of claim 1, further comprising a first controller, a second controller, and an inter-controller commissure, wherein said first controller controls said switches on said first die, wherein said second controller controls switches on said second die, wherein said inter-controller commissure provides a link between said first and second controllers to permit operation of said first switches to depend at least in part on operation of said second switches, and to permit operation of said second switches to depend at least in part on operation of said first switches.

3. The apparatus of claim 2, wherein said first controller is on said first die and wherein said second controller is on said second die, and wherein said inter-controller commissure extends between said first die and said second die.

4. The apparatus of claim 2, further comprising a third die and a fourth die, wherein said first controller is on said third die and wherein said second controller is on said fourth die, and wherein said inter-controller commissure extends between said third die and said fourth die.

5. The apparatus of claim 1, wherein said switched-capacitor converter is a two-phase converter, wherein said apparatus further comprises a third die and a fourth die, wherein said stack switches comprise a first set of stack switches and a second set of stack switches, each of which is associated with one of said two phases, wherein said first set of stack switches is on said second die and said second set of stack switches is on said fourth die, wherein said phase switches comprise a first set of phase switches and a second set of phase switches, each of which is associated with one of said two phases, and wherein said first set of phase switches is on said first die and said second set of phase switches is on said third die.

6. The apparatus of claim 1, further comprising charge-transfer capacitors connected to said stack switches and to said phase switches.

7. The apparatus of claim 6, wherein said charge-transfer capacitors are selected to have capacitances that are a function of voltage applied across said charge-transfer capacitors, wherein, in operation, said charge-transfer capacitors sustain different maximum voltages, and wherein said charge-transfer capacitors are selected such that, when at their respective maximum voltages, said charge-transfer capacitors all have the same capacitance.

8. The apparatus of claim 6, further comprising a third die, wherein said charge-transfer capacitors are integrated into said third die.

9. The apparatus of claim 6, wherein said charge-transfer capacitors are discrete capacitors that connect to said first and second dies.

10. The apparatus of claim 6, wherein said first die and said second die are connected via an inter-die commissure having a length that corresponds to a distance between positive and negative terminals of said charge-transfer capacitors.

11. The apparatus of claim 10, wherein said interdie commissure has a first region and a second region, wherein, during operation, said first region carries more current than said second region, and wherein said first region is wider than said second region.

12. The apparatus of claim 6, further comprising an interdie commissure connecting said first and second dies, wherein said first die and said second die contain first terminals for connection to positive terminals of said charge-transfer capacitors, and second terminals for connection to negative terminals of said charge-transfer capacitors, wherein said first terminals and said second terminals are disposed on opposite ends of said interdie commissure, wherein said charge-transfer capacitors are oriented such that positive terminals thereof lie closer to said first terminals than they do to said second terminals and negative terminals thereof lie closer to said second terminals than to said first terminals.

13. The apparatus of claim 1, further comprising an interdie commissure connecting said first and second dies, wherein said interdie commissure is folded such that said first and second dies lie on different planes.

14. The apparatus of claim 1, wherein said first and second dies lie on different planes.

15. The apparatus of claim 1, wherein said switched-capacitor converter is a multi-phase converter, said apparatus further comprising a third die, wherein said phase switches comprise a first set of phase switches associated with a first phase and a second set of phase switches associated with a second phase, wherein said first set is on said first die and said second set is on said second die.

16. The apparatus of claim 15, further comprising first and second sets of charge-transfer capacitors, wherein said first set of charge-transfer capacitors is connected between said first die and said second die, and wherein said second set of charge-transfer capacitors is connected between said third die and said second die.

17. The apparatus of claim 1, further comprising a substrate and charge-transfer capacitors, wherein said substrate supports said charge-transfer capacitors, said first die, and said second die.

18. The apparatus of claim 17, further comprising a package, wherein said first and second dies are in said package.

19. The apparatus of claim 18, wherein said first and second dies are coplanar.

20. The apparatus of claim 18, wherein said first and second dies are on different planes within said package.

21. The apparatus of claim 17, wherein device faces of said first and second dies face said substrate, and wherein conducting bumps between said device face and said substrate provide electrical communication between said dies and said charge-transfer capacitors.

22. The apparatus of claim 1, further comprising a substrate, a package, a third die, and charge-transfer capacitors, wherein said charge-transfer capacitors are integrated into said third die, wherein said substrate supports said package, wherein said package includes said first die, said second die, and said third die, wherein said first, second, and third dies are distributed among different layers of said package.

23. The apparatus of claim 22, wherein said package comprises a first layer and a second layer, wherein said first and second dies are in said first layer and said third die is in said second layer.

24. The apparatus of claim 22, wherein said package comprises a first layer and a second layer, wherein said first and third dies are in said first layer and said second die is in said second layer.

25. The apparatus of claim 22, wherein said package comprises a first layer, a second layer, and a third layer, wherein each layer contains at most one die.

26. The apparatus of claim 25, wherein said second layer is between said first and third layers, and wherein said third die is in said second layer.

27. The apparatus of claim 1, further comprising a substrate, a package, an inductor, and charge-transfer capacitors, wherein said substrate supports said package, wherein said package comprises a lower layer and an upper layer, wherein said lower layer is closer to said substrate than said upper layer, wherein a die is in said lower layer, wherein said charge-transfer capacitors are in said upper layer, and wherein said inductor is on said substrate outside said package, wherein said die is selected from said first and second dies.

28. The apparatus of claim 27, wherein a device face of said die faces said substrate, said apparatus further comprising a first interconnect layer, a second interconnect layer, and electrically conducting bumps, wherein said first interconnect layer connects said charge-transfer capacitors to said die, wherein said second interconnect layer connects said die to said charge-transfer capacitors and to said electrical bumps, and wherein said electrical bumps connect said package with said inductor.

29. The apparatus of claim 27, wherein a device face of said die faces away from said substrate, further comprising a heat sink, thermally-conducting bumps, a first interconnect layer, a second interconnect layer, and electrically-conducting bumps, wherein said first interconnect layer connects said charge-transfer capacitors to said die, wherein said second interconnect layer connects said die to said charge-transfer capacitors and to said electrically-conducting bumps, wherein said electrically-conducting bumps connect said package with said inductor, wherein said heat sink faces said substrate, wherein said thermally-conducting bumps connect said heat sink to said substrate, and wherein said thermally-conducting bumps carry only heat and are electrically disconnected from said circuit.

30. The apparatus of claim 27, wherein a device face of said die faces away from said substrate, wherein said apparatus further comprises a heat sink, a thermally-conducting pad, a first interconnect layer, a second interconnect layer, and electrically conducting pads, wherein said first interconnect layer connects said charge-transfer capacitors to said die, wherein said second interconnect layer connects said die to said charge-transfer capacitors and to said electrically conducting pads, wherein said electrically conducting pads connect said package with said inductor, wherein said heat sink faces said substrate, wherein said thermally-conducting pad connects said heat sink to said substrate, and wherein said thermally-conducting pad carries only heat and is electrically isolated from said inductor, said charge-transfer capacitor, and said die.

31. The apparatus of claim 1, further comprising a substrate, a package, an inductor, and charge-transfer capacitors, wherein said substrate supports said package, wherein said package comprises a lower layer and an upper layer, wherein said inductor is in said package, wherein said lower layer is closer to said substrate than said upper layer, wherein a die is in said lower layer, wherein said charge-transfer capacitors are in said upper layer, and wherein said die is selected from said first and second dies.

32. The apparatus of claim 31, wherein said inductor is disposed in said upper layer.

33. The apparatus of claim 31, wherein said inductor comprises an inductor core and conductive traces forming windings of said inductor in said lower layer.

34. The apparatus of claim 31, further comprising a heat sink and thermally-conducting bumps, wherein a device face of said chip faces away from said substrate, wherein said heat sink faces said substrate, wherein said thermally-conducting bumps connect said heat sink to said substrate, and wherein said thermally-conducting bumps only carry heat and are isolated from said die, said charge-transfer capacitors, and said inductor.

35. The apparatus of claim 1, further comprising regulator switches, wherein said regulator switches are in said first die.

36. The apparatus of claim 1, further comprising a filter, a controller, and a transformation stage that cooperate with said switches to carry out power conversion, wherein said transformation stage is configured for transforming a first voltage into a second voltage, wherein said switches define a switching network for said transformation stage, said switches being independently controlled so as to cause said switching network to transition between at least first and second switching arrangements, wherein said filter is configured to connect said transformation stage to a regulator, and wherein said controller controls said switching network by causing said switching network to transition between said first and second switching arrangements.

37. The apparatus of claim 36, wherein said filter comprises an LC filter.

38. The apparatus of claim 37, wherein said filter is configured to connect said transformation stage to more than one regulator.

39. The apparatus of claim 36, wherein said filter comprises an inductance that, in operation at a particular switching frequency, sustains a peak-to-peak voltage ripple and supports an inductor current that passes into a load, said inductor current defining an average inductor current.

40. The apparatus of claim 39, wherein said inductance is proportional to a value selected by dividing said peak-to-peak voltage ripple by a product of said average inductor current and said switching frequency.

41. The apparatus of claim 40, wherein a constant of proportionality by which said value is multiplied to obtain said inductance is 13/24.

42. The apparatus of claim 36, further comprising said regulator.

43. The apparatus of claim 36, further comprising plural regulators, wherein said filter connects said transformation stage to all of said regulators.

44. The apparatus of claim 36, wherein said transformation stage comprises plural switching networks, and wherein said filter is configured to connect all of said switching networks to a regulator.

45. The apparatus of claim 36, wherein said transformation stage comprises a plurality of units in series, each unit comprising a switching network in series with a filter.

46. The apparatus of claim 36, wherein said filter comprises an inductance that constrains a rate at which an amount of charge stored in a capacitor in said transformation stage changes in response to a transition between said first and second switching arrangements.

47. The apparatus of claim 36, wherein said transformation stage is adiabatically charged.

48. The apparatus of claim 1, wherein said first and second dies are configured according to said first configuration.

49. The apparatus of claim 1, wherein said first and second dies are configured according to said second configuration.

50. The apparatus of claim 1, wherein, in response to a transition between said first and second switch arrangements, a rate at which charge present on a capacitor in said switched-capacitor network changes is constrained by an inductance.