US-20260128671-A1 - STACKED POWER CONVERTER ASSEMBLIES

US20260128671A1US 20260128671 A1US20260128671 A1US 20260128671A1US-20260128671-A1

Abstract

A power converter assembly includes a stack of circuit components to convert an input voltage into an output voltage. The stack of circuit components may include: a first component layer including driver circuitry; a second component layer including multiple switches controlled by the driver circuitry in the first component layer; and a third component layer disposed between the first component layer and the second component layer, the third component layer comprising at least one capacitor component to support conversion of the input voltage into the output voltage. In another implementation, the power converter assembly includes: a first component layer including at least one capacitor component of the power converter; a second component layer coupled to the first component layer, the second component layer including driver circuitry and multiple switches; and a third component layer including at least one inductor.

Inventors

Sutej Reddy Challa
EungSan Cho
Darryl Tschirhart
Danny R. Clavette
Wenkang Huang
Darryl Galipeau
Matthew Straayer

Assignees

INFINEON TECHNOLOGIES AUSTRIA AG

Dates

Publication Date: 20260507
Application Date: 20241104

Claims (20)

1 . An apparatus comprising: a power converter assembly including a stack of circuit components, the power converter assembly operative to convert an input voltage into an output voltage, the stack of circuit components including: a first component layer including switch driver circuitry; a second component layer including multiple switches controlled by the switch driver circuitry in the first component layer; and a third component layer disposed between the first component layer and the second component layer, the third component layer comprising at least one capacitor component to support conversion of the input voltage into the output voltage.
2 . The apparatus as in claim 1 further comprising: electrically conductive paths extending through the third component layer, the electrically conductive paths operative to convey control signals from the switch driver circuitry to the multiple switches.
3 . The apparatus as in claim 1 further comprising: a first redistribution layer disposed between the first component layer and the third component layer; and a second redistribution layer disposed between the third component layer and the second component layer.
4 . The apparatus as in claim 1 , wherein the multiple switches in the second component layer include a first switch circuit and a second switch circuit; and a circuit component disposed in the second component layer between the first switch circuit and the second switch circuit.
5 . The apparatus as in claim 1 , wherein the at least one capacitor component includes: a first capacitor operative to store the input voltage; a second capacitor operative to store a driver voltage used by the switch driver circuitry; and a third capacitor operative to store the output voltage.
6 . The apparatus as in claim 1 , wherein the at least one capacitor component in the third component layer includes: a bootstrap capacitor connected between the switch driver circuitry in the first component layer and a first axial end of a first electrically conductive path in a third component layer of the power converter assembly.
7 . The apparatus as in claim 1 , wherein the stack of circuit components further includes: a fourth component layer comprising: magnetically permeable material; and a first electrically conductive path encompassed by the magnetically permeable material.
8 . The apparatus as in claim 7 , wherein the first electrically conductive path is operative to convey first current in a first direction away from the second component layer through the fourth component layer to a load, the power converter assembly further comprising: a second electrically conductive path encompassed by the magnetically permeable material, the second electrically conductive path operative to convey the first current in a second direction from the load through the fourth component layer.
9 . The apparatus as in claim 8 , wherein the second electrically conductive path is a single homogeneous element of metal extending through the fourth component layer, the second electrically conductive path disposed between the first electrically conductive path and a third electrically conductive path in the fourth component layer, the third electrically conductive path operative to convey second current in the first direction to the load.
10 . The apparatus as in claim 1 further comprising: a host substrate; a load; and wherein the stack of circuit components is disposed between the host substrate and the dynamic load, the stack of circuit components operative to receive the input voltage from the host substrate and supply the output voltage to the dynamic load.
11 . The apparatus as in claim 1 , wherein the second component layer includes at least one capacitor.
12 . The apparatus as in claim 1 further comprising: a host package substrate including a cavity; and wherein the stack of circuit components is disposed in the host package substrate.
13 . The apparatus as in claim 1 , wherein the third component layer is fabricated from: i) glass, ii) silicon; or iii) a multi-compound layer of material.
14 . An apparatus comprising: a power converter assembly including a stack of power converter components, the power converter assembly operative to convert an input voltage into an output voltage, the stack of power converter components including: a first component layer including at least one capacitor component; a second component layer coupled to the first component layer, the second component layer including switch driver circuitry and multiple switches, the multiple switches controlled by the switch driver circuitry; a third component layer coupled to the second component layer, the third component layer including at least one inductor; and wherein the second component layer is disposed between the first component layer and the third component layer.
15 . The apparatus as in claim 14 further comprising: a first redistribution substrate disposed between the first component layer and the second component layer; and a second redistribution substrate disposed between the second component layer and the third component layer.
16 . The apparatus as in claim 14 , wherein the at least one capacitor component includes: a first capacitor operative to store the input voltage; and a second capacitor operative to store a driver voltage used by the driver circuitry.
17 . The apparatus as in claim 1 , wherein the third component layer includes: magnetically permeable material; and a first electrically conductive path encompassed by the magnetically permeable material, the first electrically conductive path extending axially from a first node disposed on a first surface of the third component layer and a second node disposed on a second surface of the third component layer, the second surface disposed opposite the first surface.
18 . The apparatus as in claim 17 , wherein the first electrically conductive path is operative to convey first current received from the second component layer through the third component layer in a first direction to a load, the apparatus further comprising: a second electrically conductive path encompassed by the magnetically permeable material, the second electrically conductive path operative to convey the first current in a second direction from the load through the third component layer to the second component layer.
19 . The apparatus as in claim 18 , wherein the second electrically conductive path is a single homogeneous element of metal extending through the third layer, the second electrically conductive path disposed between the first electrically conductive path and a third electrically conductive path in the third component layer, the third electrically conductive path operative to convey second current in the first direction; and wherein the second electrically conductive path is operative to convey the second current in the second direction from the load through the third component layer to the second component layer.
20 . An assembly comprising: a host substrate; the stack of circuit components as in claim 14 coupled to the host substrate; a dynamic load coupled to the stack of circuit components; and wherein the stack of circuit components is disposed between the host substrate and the dynamic load, the stack of circuit components operative to receive the input voltage from the host substrate and supply the output voltage to the dynamic load.

Description

BACKGROUND Conventional switching power supply circuits sometimes include an energy storage component such as an inductor to produce an output voltage that powers a load. For example, to maintain a magnitude of an output voltage within a desired range, a controller controls switching of input current through one or more inductors. In general, a conventional inductor is a component comprising wire or other conductive material, which is shaped as a coil or helix to increase an amount of magnetic flux through a respective circuit path. Winding a wire into a coil of multiple turns increases the number of respective magnetic flux lines in a respective inductor component, increasing the magnetic field and thus overall inductance of the respective inductor component. Certain conventional power converters include a stacking of components to convert a respective input voltage into an output voltage. BRIEF DESCRIPTION Examples herein provide novel and improved inductor components as well as novel and improved stacked power converter topologies. Power Converter Assembly Including First Stack of Circuit Components First examples herein include a novel power converter assembly and a method of fabricating same. In one example, an apparatus as discussed herein includes a power converter assembly. The power converter assembly comprises a stack of circuit components. The power converter assembly and stack of circuit components is operative to convert an input voltage into an output voltage. The stack of circuit component can be configured to include: a first component layer including switch driver circuitry; a second component layer including multiple switches controlled by the switch driver circuitry in the first component layer; and a third component layer disposed between the first component layer and the second component layer, the third component layer comprising at least one capacitor component to support conversion of the input voltage into the output voltage. In another example, as discussed herein, the apparatus and corresponding stack of circuit components may include electrically conductive paths extending through the third component layer, where the electrically conductive paths operative to convey control signals from the switch driver circuitry to the multiple switches. Additionally, the apparatus as discussed herein may be configured to include: a first redistribution layer disposed between the first component layer and the third component layer; and a second redistribution layer disposed between the third component layer and the second component layer. Yet further, the multiple switches in the second component layer may include a first switch circuit and a second switch circuit; and a circuit component may be disposed in the second component layer between the first switch circuit and the second switch circuit. In another example, the at least one capacitor component includes: a first capacitor operative to store the input voltage; a second capacitor operative to store a driver voltage used by the switch driver circuitry; and a third capacitor operative to store the output voltage. In still further examples, the at least one capacitor component may include: a bootstrap capacitor connected between the switch driver circuitry in the first component layer and a first axial end of a first electrically conductive path in a third component layer of the power converter assembly. In one example, the bootstrap capacitor is connected to two switches. As another example, the stack of circuit components may include: a fourth component layer comprising: magnetically permeable material; and a first electrically conductive path encompassed by the magnetically permeable material. The first electrically conductive path can be configured to convey first current in a first direction away from the second component layer through the fourth component layer to a load. The power converter assembly may further include a second electrically conductive path encompassed by the magnetically permeable material, the second electrically conductive path operative to convey the first current in a second direction from the load through the fourth component layer. The second electrically conductive path may be fabricated from a single homogeneous element of metal extending through the fourth component layer, where the second electrically conductive path is disposed between the first electrically conductive path and a third electrically conductive path in the fourth component layer, and where the third electrically conductive path is operative to convey second current in the first direction to the load. Still further, and assembly as discussed herein can be configured to include a host substrate and a load. The stack of circuit components may be disposed between the host substrate and the dynamic load, where the stack of circuit components is operative to receive the input voltage from the host substrate and supply the output voltage to the dyna