A PCB system integration concept for power electronics

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Abstract

Abstract
Current passive components construction technologies and power converters manufacturing methods are the main barriers limiting the power density improvement. In this paper a new PCB system integration concept for power converters construction - power sandwich, that allows for a high density packaging, effective thermal management and automated manufacturing is introduced. In the Power sandwich integration concept new passive components, x-dimension components, having the same height (x) and double sided electrical terminations are stacked between planar substrates and soldered on two sides. Depending on the number of stack layers (x-layers) and the components loss density, various arrangements in the power sandwich converter is possible. A power sandwich demonstrator, 70 W flyback converter, is designed and implemented using modified standard components representing the prototype of x-dimension components. The spatial and thermal designs are discussed in detail and the experimental results of the first power sandwich demonstrator are shown.

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