Power-one Limited

Pai Capital LLC

Urs Wild

Ivan Feno

Nicola Cinagrossi

Evan Espina

A dense and efficient output stage for a DC/DC converter includes center tapped secondary windings of a transformer having an offset core with respect to a PCB, two pairs of synchronous rectifiers configured to define two pairs of paralleled symmetrical AC loops respective to the secondary windings, and at least two bus bars disposed within a forced cooling airstream to act as heat sinks for the synchronous rectifiers, while further providing a filtering impedance between the transformer windings and an output capacitance. A split capacitance is disposed in close proximity with the synchronous rectifiers to filter out ripple current, in one embodiment characterized by first and second capacitors each respectively coupled between opposing ends of the first and second bus bars, wherein the bus bars are arranged about at least three sides of the transformer core.

Power converter output stage using heat dissipating bus bars

A multiphase DC-DC converter includes multiple groups of first and second LLC power trains coupled in parallel which collectively provide an output voltage to a load. A voltage feedback control loop senses an output voltage for the LLC converter and generates an identical reference current signal for each of the multiple groups of power trains, the signals representing a reference current based on the sensed output voltage, wherein an active current sharing operation is provided between each of the groups. A local current control loop for each of the groups generates PWM control signals to each of the respective first and second power trains based on the reference current, the PWM control signals having an identical frequency but out of phase with respect to each other, wherein a passive current sharing operation is provided within each of the plurality of power groups.

Multiphase converter with active and passive internal current sharing

A slotted bobbin magnetic component device includes a bobbin having an elongated bobbin tube with transverse slots. One or more substantially flat electrically conductive winding inserts are inserted radially onto the bobbin tube via the transverse slots. At least one detent positioned on the winding insert secures the winding insert on the bobbin and prevents the winding insert from becoming misplaced relative to the bobbin. One or more flanges protruding from the bobbin engage one or more corresponding recesses on the winding insert to prevent angular movement of the winding insert relative to the bobbin. One or more primary conductive winding coils are disposed about the bobbin in the gaps between adjacent winding inserts, the coils being formed by axially winding numerous layers over each other in alternating axial winding directions.

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Bäretswil, Switzerland

Urs Wild