en fr

Intégration d'un convertisseur de 3.3 kW en utilisant la technologie d'enfouissement PCB

Integration of a 3.3 kW, AC/DC Bidirectional Converter using Printed Circuit Board Embedding Technology

Abstract : Today, the efficient management of the electrical energy relies on power electronic converters. The conception of a converter is a multiphysic problem: the converter has to ensure electrical functionality, mechanical support and proper thermal management. The new wide-band gap components hold the key for dramatic improvement in performance, but they are currently limited by their package. The integration of a converter should use new interconnection methods to avoid the use of packaged components. The trend is to integrate the maximum of components into a single system. This integration can offer benefits such as size and weight reduction, cost saving and reliability improvement by managing the complexity of the interconnects. Among many integration technologies available, Printed Circuit Board (PCB) is well known in the industry, allowing mass production with automated manufacturing and assembly. The PCB integration was developed with the “Die Embedding” technology in which a bare die is embedded directly in the PCB without any intermediate package. This thesis investigates the use of the embedding technology on all the components necessary to build a converter (Capacitors, Magnetics, ...). An optimization of the converter is done to take into account the advantages of this new technology. A prototype of an AC/DC bidirectional converter fully integrated using this technology is presented, and its performances are discussed. The embedding processes are developed according to the routing to achieve the best thermal and EMI performances. The process yield is very high (97% for the die board). The "Embedded Toroidal" inductors manufactured present some issues. There were replaced by more standard "Planar" inductor to work at nominal power. The achieved power density is 2.6kW/L for the two first stages. Some propositions are given to achieve the specification of 4.2kW/L.