Chip embedded power converters
A direct current to direct current (DC-DC) converter can include a chip embedded integrated circuit (IC), one or more switches, and an inductor. The IC can be embedded in a PCB. The IC can include driver, switches, and PWM controller. The IC and/or switches can include eGaN. The inductor can be stacked above the IC and/or switches, reducing an overall footprint. One or more capacitors can also be stacked above the IC and/or switches. Vias can couple the inductor and/or capacitors to the IC (e.g., to the switches). The DC-DC converter can offer better transient performance, have lower ripples, or use fewer capacitors. Parasitic effects that prevent efficient, higher switching speeds are reduced. The inductor size and overall footprint can be reduced. Multiple inductor arrangements can improve performance. Various feedback systems can be used, such as a ripple generator in a constant on or off time modulation circuit.
1. A method of making a power converter, the method comprising:
embedding circuitry in a printed circuit board (PCB) that includes an upper side and a lower side so that the circuitry is chip-embedded between the upper side of the PCB and the lower side of the PCB, wherein the embedded circuitry including one or more switches;
providing a driver coupled to the one or more switches and configured to generate one or more driver signals for driving the one or more switches; and
electrically coupling an inductor to the embedded circuitry, wherein the inductor is external to the PCB and positioned over the upper side of the PCB, and wherein a footprint of the inductor at least partially overlaps a footprint of the embedded circuitry;
providing an input terminal that is coupled to the embedded circuitry, the input terminal configured to receive an input voltage; and
providing an output terminal that is coupled to the inductor, the output terminal configured to provide an output voltage that is different than the input voltage, wherein the output voltage is based, at least in part, on the one or more switches causing the inductor to charge and discharge.
2. The method of claim 1 , wherein one or more vias extend through the upper side of the PCB to electrically couple the inductor to the embedded circuitry.
3. The method of claim 1 , wherein the embedded circuitry includes the driver.
4. The method of claim 1 , wherein the embedded circuitry comprises a pulse width modulator (PWM) controller configured to generate one or more PWM signals, wherein the PWM controller is coupled to the driver, and wherein the driver is configured to generate the one or more driver signals based at least in part on the PWM signals.
5. The method of claim 1 , wherein the one or more switches includes a first enhanced gallium nitride (eGaN) switch and a second eGaN switch.
6. The method of claim 1 , comprising providing a ramp generator configured to generate a signal that emulates a current ripple through the inductor.
7. The method of claim 1 , providing an isolated topology that isolates a direct electrical connection between the input terminal and the output terminal of the power converter.
8. The method of claim 1 , wherein one of the inductor and the embedded circuitry has a footprint entirely within a footprint of the other of the inductor and the embedded circuitry.
9. The method of claim 1 , comprising providing a communication interface that is configured to receive a control signal for adjusting an output of the power converter.
10. The method of claim 1 , wherein the power converter comprises an AC coupling capacitor.
11. The method of claim 1 , wherein the one or more switches includes a first enhanced gallium nitride (eGaN) switch and a second eGaN switch.
12. The method of claim 1 , comprising generating a signal that emulates a current ripple through the inductor using a ramp generator.
13. The method of claim 12 , wherein the ramp generator is configured to generate the signal that emulates the current ripple through the inductor at least in part using:
a first input indicative of the input voltage;
a second input indicative of the output voltage;
a third input indicative of an inductance value of the inductor; and
a fourth input of a switching signal.
14. A method for using a power converter, the method comprising:
receiving input voltage at an input node;
providing the input voltage to embedded circuitry that is chip-embedded between an upper side of the a printed circuit board (PCB) and a lower side of the PCB, wherein the embedded circuitry including one or more switches;
generating one or more driver signals for driving the one or more switches and delivering the one or more driver signals to the one or more switches;
charging and discharging an inductor that is electrically coupled to the embedded circuitry based on driving of the one or more switches, wherein the inductor is external to the PCB and positioned over the upper side of the PCB, and wherein a footprint of the inductor at least partially overlaps a footprint of the embedded circuitry;
providing an output voltage to an output terminal that is coupled to the inductor, the output configured to provide an output voltage that is different than the input voltage, wherein the output voltage is based, at least in part, on the one or more switches causing the inductor to charge and discharge.
15. The method of claim 14 , wherein one or more vias extend through the upper side of the PCB to electrically couple the inductor to the embedded circuitry.
16. The method of claim 14 , wherein the embedded circuitry includes a driver that generates the one or more driver signals.
17. The method of claim 14 , wherein the power converter has an isolated topology that isolates a direct electrical connection between the input terminal and the output terminal of the power converter.
18. The method of claim 14 , wherein one of the inductor and the embedded circuitry has a footprint entirely within a footprint of the other of the inductor and the embedded circuitry.
19. The method of claim 14 , comprising adjusting an output of the power converter using a control signal received via a communication interface.
20. The method of claim 14 , wherein the power converter comprises an AC coupling capacitor.