High integration and Moore's Law are very effective in reducing the size of the device, but not very good for DC (DC/DC) converters, because power converters often take up 30% to 50% of the system space. So, how can we break through this bottleneck?
Increasing the frequency of work is undoubtedly an obvious solution. Most point-of-load regulators are switching converters with a buck topology. Increasing the switching frequency reduces the inductance and capacitance required to meet the regulator's design specifications. Since inductors and capacitors typically occupy most of the DC/DC converter space, as shown in Figure 1(a), this can be very effective. But in fact it is not that simple. So, why is it?
Figure 1: Size comparison of 12VIN at 10kHz, 10AOUT step-down converter (a) and series capacitor (b) at 2MHz per phase
Blindly increasing the frequency increases power consumption. The switching frequency is proportional to the loss, and each time the power is turned on, energy is generated. Among them, the reduction of conversion efficiency and heat dissipation may be the main problems. Today, most converters are limited in frequency to hundreds of kilohertz. Converters with frequencies above 1 MHz are typically of the typical low voltage (5V and below) and low current (less than 1A) types.
It's time to look for other solutions outside of the buck. Buck converters have been the industry's main choice for decades, but they also have fundamental flaws. Now, we have introduced a new DC/DC converter topology that is optimized for high voltage conversion than point-of-load applications. The series capacitor buck converter achieves an operating frequency of several megahertz without affecting efficiency. As shown in Figure 1(b), the overall solution size has been significantly reduced. The TPS54A20-based series capacitor buck converter has the same input and output conditions as the buck converter in Figure 1(a), which is eight times smaller than the latter. That is 1,270 mm3 vs 157 mm3.
Figure 2: Height comparison of 12 VIN at 10 kHz, 10 AOUT buck converter (a) and series capacitor at 2 MHz per phase (b)
The reduction in the size of the regulator gives us more opportunities. Comparing the height profile shown in Figure 2, we can see that the conventional buck converter has a height of 4.8 mm, but for the back part, this height is much higher than the height limit of many systems. The low profile of the series capacitor buck converter (1.2 mm high) allows you to place the regulator on the back of the board, which frees up valuable top side substrate surfaces. It was not realistic to put the entire 10A converter on its back before, because the passive components were too large, but with the TPS54A20, everything is possible.
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