IP Library Granted Patent US 12,457,687
Granted Patent B2
US 12,457,687 · App. 18/255,853 · Granted Oct 28, 2025

Stacked component array structure

Inventors: Jin Zhao (San Jose, CA); Satyan Chandra (Mountain View, CA); Shishuang Sun (San Jose, CA)
Assignee: Tesla, Inc.
H05K1/113H05K3/328H05K3/3436H05K3/3442H05K2201/10015H05K2201/10636H05K2201/10734H05K2203/101H05K2203/107
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Quick Facts
Patent No.
US 12,457,687
App. No.
18/255,853
Granted
Oct 28, 2025
Kind
B2
Abstract

A structure with an electronic component array positioned between two stacked printed circuit boards ( 600,606 ) is disclosed. The electronic components ( 502 ) of the array can be connected to the printed circuit board ( 600,606 ) by way of solder connections. Example electronic components ( 502 ) include capacitors. Related methods of manufacture are disclosed that involve applying heat to a solder paste array on a printed circuit board ( 600,606 ) to form solid conductors electrically connected to the electronic components ( 502 ).

Claims (34)

1. A stacked Printed Circuit Board (PCB) electronic component array structure comprising:

a first PCB;

a second PCB, the second PCB being stacked with the first PCB; and

an electronic component array comprising a plurality of electronic components positioned between the first PCB and the second PCB, the electronic component array comprising a plurality of capacitors, the plurality of electronic components being electrically coupled to the first PCB by way of a first conductive strip connections and being electrically coupled to the second PCB by way of second conductive strip connections, wherein a first conductive strip connection of the first conductive strip connections provides a shared electrical connection between a group of capacitors of the plurality of capacitors and the first PCB.

2. The stacked PCB electronic component array structure of claim 1 , wherein:

first sides of the plurality of electronic components electrically couple to both the first PCB and the second PCB; and

second sides of the plurality of electronic components electrically couple to both the first PCB and the second PCB.

3. The stacked PCB capacitor array structure of claim 2 , wherein:

an inner surface of the first PCB couples to the plurality of electronic components of the electronic components array; and

an inner surface of the first PCB couples to the plurality of electronic components of the electronic components array.

4. The stacked PCB capacitor array structure of claim 2 , further comprising:

a first ball grid array disposed on an outer surface of the first PCB, the plurality of electronic components being electrically coupled to the first ball grid array by way of first vias in the first PCB; and

a second ball grid array disposed on an outer surface of the second PCB, the plurality of electronic components being electrically coupled to second first ball grid array by way of second vias in the second PCB.

5. The stacked PCB electronic component array structure of claim 1 , wherein the group of capacitors is electrically connected in parallel with each other, and the plurality of capacitors comprise a second group of capacitors electrically connected in series with each other.

6. The stacked PCB electronic component array structure of claim 1 , wherein the stacked PCB electronic component array is implemented in a voltage regulator module (VRM).

7. The stacked PCB electronic component array structure of claim 1 , wherein a second conductive strip connection of the second conductive strip connections electrically connects the group of electronic components of the plurality of capacitors to the second PCB.

8. A stacked Printed Circuit Board (PCB) electronic component array structure comprising:

a first PCB;

a second PCB, the second PCB being stacked with the first PCB; and

a two-dimensional electronic component array comprising a plurality of electronic components positioned between the first PCB and the second PCB, the plurality of electronic components being electrically coupled to the first PCB by way of first solder connections and being electrically coupled to the second PCB by way of second solder connections, wherein a first common solder connection of the first solder connections electrically connects a group of electronic components of the plurality of electronic components to the first PCB, and wherein a second common solder connection of the second solder connections electrically connects the group of electronic components of the plurality of electronic components to the second PCB.

9. The stacked PCB electronic component array structure of claim 8 , wherein the plurality of electronic components are capacitors.

10. The stacked PCB electronic component array structure of claim 9 , wherein the stacked PCB electronic component array is implemented in a voltage regulator module (VRM) that is configured to receive a voltage and convert the voltage to a lower voltage.

11. The stacked PCB electronic component array structure of claim 8 , wherein a third common solder connection of the first solder connections electrically connects a second group of electronic components of the plurality of electronic components to the first PCB, and wherein a fourth common solder connection of the second solder connections electrically connects the second group of electronic components of the plurality of electronic components to the second PCB.

12. A voltage regulator module comprising:

a first printed circuit board (PCB);

a second PCB, the second PCB being stacked with the first PCB; and

a two-dimensional capacitor array positioned between the first PCB and the second PCB, wherein a first common solder connection electrically connects a group of capacitors of the two-dimensional capacitor array to the first PCB,

wherein the voltage regulator module is configured to receive a voltage and convert the voltage to a lower voltage.

13. The voltage regulator module of claim 12 , wherein a second common solder connection electrically connects the group of capacitors of the two-dimensional capacitor array to the second PCB.

14. The voltage regulator module of claim 12 , wherein a second common solder connection electrically connects a second group of capacitors of the two-dimensional capacitor array to the first PCB.

15. The voltage regulator module of claim 12 , wherein the capacitors of the group are connected in series with each other.

16. The voltage regulator module of claim 12 , wherein the voltage is in a range from 40 Volts to 60 Volts.

17. The voltage regulator module of claim 16 , wherein the lower voltage is less than 1 Volt.

18. The voltage regulator module of claim 12 , wherein the voltage regulator module outputs over 100 Amperes of current.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 26, 2025
From: ZHAO, JIN; CHANDRA, SATYAN; SUN, SHISHUANG
To: TESLA, INC.
Reel/Frame 072390/0058 →
Continuity (2)
Provisional Application 63127018 · Dec 17, 2020
Related Publication 20240015887A1 · Jan 11, 2024
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