US20140185245A1 - Switching circuit layout with heatsink - Google Patents
Switching circuit layout with heatsink Download PDFInfo
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- US20140185245A1 US20140185245A1 US14/143,699 US201314143699A US2014185245A1 US 20140185245 A1 US20140185245 A1 US 20140185245A1 US 201314143699 A US201314143699 A US 201314143699A US 2014185245 A1 US2014185245 A1 US 2014185245A1
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- circuit board
- switching converter
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0201—Thermal arrangements, e.g. for cooling, heating or preventing overheating
- H05K1/0203—Cooling of mounted components
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0213—Electrical arrangements not otherwise provided for
- H05K1/0216—Reduction of cross-talk, noise or electromagnetic interference
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
- H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0201—Thermal arrangements, e.g. for cooling, heating or preventing overheating
- H05K1/0203—Cooling of mounted components
- H05K1/021—Components thermally connected to metal substrates or heat-sinks by insert mounting
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/182—Printed circuits structurally associated with non-printed electric components associated with components mounted in the printed circuit board, e.g. insert mounted components [IMC]
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09209—Shape and layout details of conductors
- H05K2201/09372—Pads and lands
- H05K2201/09418—Special orientation of pads, lands or terminals of component, e.g. radial or polygonal orientation
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10007—Types of components
- H05K2201/10166—Transistor
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10431—Details of mounted components
- H05K2201/10507—Involving several components
- H05K2201/10522—Adjacent components
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0058—Laminating printed circuit boards onto other substrates, e.g. metallic substrates
- H05K3/0061—Laminating printed circuit boards onto other substrates, e.g. metallic substrates onto a metallic substrate, e.g. a heat sink
Definitions
- the present invention relates to switching converters and to specifically a circuit layout of four switches
- thermal resistance of materials used to package electronic components is of great interest to electronic engineers, because most electrical components generate heat and need to be cooled. Electronic components need to be cooled to avoid premature aging and consequent failure. Also, effective cooling of the electronic component(s) susceptible to generating heat in a circuit allows for a stable, efficient and predictable performance of the circuit. In particular, heat generated from electronic components in power supply/conversion circuits are mostly derived from the main switching devices.
- Heat sinks function by efficiently transferring thermal energy or heat from a first object at a relatively high temperature to a second object or the environment at a lower temperature with a much greater heat capacity. This rapid transfer of thermal energy quickly brings the first object into thermal equilibrium with the second object or environment, lowering the temperature of the first object thus fulfilling the role of a heat sink as a cooling device.
- FIGS. 1 a and 1 b show a plan and side view respectively of a circuit board 100 with heat sink 102 according to conventional art.
- switches 104 are shown. Switches 104 are electrically connected to circuit board 100 via legs 106 .
- Plate 104 a is used to mechanically attach switch 104 to heat sink 102 using threaded screw 108 .
- An application of a heat sink compound (typically made from zinc oxide in a silicone base) is applied between plate 104 a and heat sink 102 prior to fastening with threaded screw 108 .
- the heat sink compound allows for better heat transfer from switch 104 and heat sink 102 to allow for the uneven surfaces of either plate 104 a or heat sink 102 .
- switch 104 is a semiconductor switch such as a metal oxide semi-conductor field effect transistor (MOSFET) or insulated gate bipolar junction transistor (IGBJT).
- MOSFET metal oxide semi-conductor field effect transistor
- IGBJT insulated gate bipolar junction transistor
- FIG. 2 a shows a conventional full bridge converter 20 .
- Full bridge DC to DC converter has four main switches S 1 , S 2 , S 3 and S 4 connected together in a full bridge configuration.
- Switches S 1 , S 2 , S 3 and S 4 are insulated gate bipolar transistors.
- the collectors of switch S 1 and switch S 3 are connected together at node Y 1 and the emitters of switch S 2 and switch S 4 are connected together at node Y 2 .
- the emitter of switch S 1 is connected to the collector of switch S 2 and the emitter of switch S 3 is connected to the collector of switch S 4 .
- Each of the four main switches (S 1 , S 2 , S 3 and S 4 ) has respective diode shunts (D 1 , D 2 , D 3 and D 4 ) connected in parallel thereto.
- the diodes placed across switches S 1 and S 2 are in both the same direction similarly the diodes of switch S 3 and switch S 4 are both in the same direction.
- all diodes (D 1 , D 2 , D 3 and D 4 ) connected across switches S 1 , S 2 , S 3 and S 4 are reverse biased with respect to the input voltage V in .
- An input voltage (V in ) of full bridge converter 20 is connected across the node (Y 2 ) between switches S 2 and S 4 and an input voltage (V in + ) is connected at the node (Y 1 ) between switches S 1 and S 3 .
- An output voltage (V out ⁇ ) of full bridge converter 20 is connected across the node (X 1 ) between switches S 1 and S 2 and output voltage V out + is connected at the node (X 2 ) between switches S 3 and S 4 .
- Switching of full bridge converter 20 is typically a 50% duty cycle such that while switches S 1 and S 4 are ON, switches S 3 and S 2 are OFF and vice versa.
- FIG. 2 b shows a typical conventional buck-boost DC-to-DC converter circuit 22 .
- the buck circuit of buck-boost DC-to-DC converter 22 has an input voltage V in with an input capacitor C 1 connected in parallel across V in .
- Two switches are implemented as field effect transistors (FET) with integral diodes: a high side buck switch Q 1 and a low side buck switch Q 2 connected in series by connecting the source of Q 1 to the drain of Q 2 .
- the drain of Q 1 and the source of Q 2 are connected parallel across an input capacitor C 1 .
- a node is formed between switches Q 1 and Q 2 to which one end of an inductor 206 is connected.
- inductor 206 is connected to the boost circuit of buck-boost DC-to-DC converter 22 at a second connecting two switches: a high side boost switch Q 4 and a low side boost switch Q 3 together in series where the source of Q 4 connects to the drain of Q 3 to form node B.
- the drain of Q 4 and the source of Q 3 connect across an output capacitor C 2 to produce the output voltage V out of buck-boost DC-to-DC converter 22 .
- High-frequency currents follow the path of least impedance (and not the path of least resistance) and a way to reduce the inductive impedance (X L 2 ⁇ fL) of parasitic inductances (L) is to reduce the frequency (f) or to reduce the size of the loop, since a longer loop gives more parasitic inductance (L).
- Power loss (P) in the loop is the product of the inductive impedance (X L ) squared and the high frequency current in the loop.
- Static power losses include I 2 R (conduction) losses in the wires or PCB traces, as well as in the switches and inductor, as in any electrical circuit. Dynamic power losses occur as a result of switching, such as the charging and discharging of the switch gate, and are proportional to the switching frequency.
- a circuit board adapted for use in an inverter for connecting a plurality of switches including a first switch, a second switch, a third switch and a fourth switch.
- the circuit board has a layout for connecting the switches.
- the layout is adapted for locating the switches substantially at the endpoints of an equilateral cross.
- the layout is adapted for locating the switches substantially symmetrically with respect to the endpoints of the equilateral cross.
- the equilateral cross is formed from two line segments of equal length intersecting at their centers with a ninety degree angle.
- the circuit board offsets all the switches perpendicularly to the line segments at the endpoints of the line segments either in a clockwise or an anticlockwise direction.
- the layout typically includes a respective cutout for the switches.
- the switches are typically chassis mounted.
- an inverter having multiple switches including a first switch, a second switch, a third switch and a fourth switch.
- a circuit board has a layout for connecting the switches. The layout locates the switches substantially at the endpoints of an equilateral cross or substantially symmetrically with respect to the endpoints of the equilateral cross.
- the switches are interconnected in a full bridge switching topology.
- the switches are interconnected in a buck-boost switching topology.
- a heat-sink is operatively attached to the switches for conducting heat from the switches.
- the switches are preferably insulated gate bipolar junction transistors (IGBT).
- the layout includes cutouts for the switches, having a chassis mounting for the insulated gate bipolar junction transistors; and a heat sink attached to the transistors and the chassis.
- the equilateral cross is formed from two line segments of equal length intersecting at their centers with a ninety degree angle.
- the circuit board may offset the switches perpendicularly to the line segments at the endpoints of the line segments either in a clockwise or an anticlockwise direction, thereby forming the layout of the switches in the shape of a fylfot cross.
- the first switch and the third switch are at the endpoints of the first line segment forming a first pair of the switches and the second switch and the fourth switch are at the endpoints of the second line segment forming a second pair of the switches.
- the inverter switches alternately the first pair of switches and the second pair of switches.
- the equilateral cross is formed from two line segments of equal length intersecting at their centers with a ninety degree angle.
- the circuit board may offset only two of the switches perpendicularly to one of the line segments at the endpoints of the one line segment either in a clockwise or an anticlockwise direction.
- the inverter is mounted vertically so that the one line segment is substantially vertical and one of the two switches is substantially below the second of the two switches so that while the inverter is operating, the heat from the lower of the two switches does not flow near the upper of the two switches.
- the first switch, the second switch, the third switch and the fourth switch may include: silicon controlled rectifier (SCR), insulated gate bipolar junction transistor (IGBT), bipolar junction transistor (BJT), field effect transistor (FET), junction field effect transistor (JFET), switching diode, electrical relay, reed relay, solid state relay, insulated gate field effect transistor (IGFET), diode for alternating current (DIAC), and/or triode for alternating current TRIAC.
- SCR silicon controlled rectifier
- IGBT insulated gate bipolar junction transistor
- BJT bipolar junction transistor
- FET field effect transistor
- JFET junction field effect transistor
- switching diode electrical relay, reed relay, solid state relay, insulated gate field effect transistor (IGFET), diode for alternating current (DIAC), and/or triode for alternating current TRIAC.
- FIG. 1 a and 1 b show a plan and side view of a circuit board with heat sink according to conventional art.
- FIG. 1 b shows a plan and side view of the circuit board with heat sink 102 shown in FIG. 1 a according to conventional art.
- FIG. 2 a shows a conventional full bridge converter according to conventional art.
- FIG. 2 b shows a typical conventional buck-boost DC-to-DC converter circuit according to conventional art.
- FIG. 3 a shows an equilateral cross topology according to an exemplary embodiment of the present invention.
- FIG. 3 b shows a fylfot cross topology according to an exemplary embodiment of the present invention.
- FIG. 3 c shows another fylfot cross topology according to an exemplary embodiment of the present invention.
- FIGS. 4 a shows a plan view of a circuit board and heat sink according to an exemplary embodiment of the present invention.
- FIG. 4 b which shows the side view of the circuit board and heat sink shown in FIG. 4 a according to an exemplary embodiment of the present invention.
- FIGS. 5 a shows a plan view of a circuit board and heat sink according to another exemplary embodiment of the present invention.
- FIG. 5 b which shows the side view of the circuit board and heat sink shown in FIG. 5 a according to an exemplary embodiment of the present invention.
- an intention of embodiments of the present invention is to minimize the lengths of the conductors between switches of a switching converter/inverter, minimizing interference due to parasitic capacitance and inductance, reducing electro-magnetic interference (EMI) emissions and thereby maximizing the efficiency of the switching converter.
- EMI electro-magnetic interference
- IGBT insulated gate bipolar junction transistors
- switch refers to any type of switch known in the art of electronics switches such as silicon controlled rectifier (SCR), insulated gate bipolar junction transistor (IGBT), metal oxide semi-conductor field effect transistor (MOSFET), bipolar junction transistor (BJT), field effect transistor (FET), junction field effect transistor (JFET), switching diode, electrical relay, reed relay, solid state relay, insulated gate field effect transistor (IGFET), DIAC, and TRIAC.
- SCR silicon controlled rectifier
- IGBT insulated gate bipolar junction transistor
- MOSFET metal oxide semi-conductor field effect transistor
- BJT bipolar junction transistor
- FET field effect transistor
- JFET junction field effect transistor
- switching diode electrical relay, reed relay, solid state relay, insulated gate field effect transistor (IGFET), DIAC, and TRIAC.
- switching converter as used herein applies to power converters, AC-to-DC converters, DC-to-AC inverters, buck converters, boost converters, buck-boost converters, full-bridge converters or any other type of electrical power conversion/inversion known in the art.
- an “equilateral cross” as used herein is a cross of two line segments (arm 36 and arm 34 ) of equal length at their center points 30 at right angles.
- the term “fylfot cross” as used herein has two arms; arm 36 and arm 34 which are crossed equilaterally at a point 32 .
- Arm 36 at each end has a hand 300 and a hand 304 which are offset perpendicular to arm 36 in an anti-clockwise direction in FIG. 3 b .
- Arm 34 at each end has a hand 302 and a hand 306 which are offset perpendicular to arm 34 in an anti-clockwise direction in FIG. 3 b .
- arm 36 at each end has a hand 312 and a hand 308 which are offset perpendicular to arm 36 in a clockwise direction.
- Arm 34 at each end has a hand 310 and a hand 314 which are offset perpendicular to arm 34 in a clockwise direction in FIG. 3 c .
- Circuit board 400 is mechanically attached to heat sink 406 for instance via a screw and pillar arrangement 410 .
- Switches S 1 , S 2 , S 3 and S 4 are mechanically and thermally attached to heat sink 406 .
- Cutouts CO 1 , CO 2 , CO 3 and CO 4 in circuit board 400 allow the mechanical and thermal attachment of switches S 1 , S 2 , S 3 and S 4 to heat sink 406 .
- switches S 1 , S 2 , S 3 and S 4 are based upon an equilateral cross topology with dotted lines 404 and 402 forming the two arms of the equilateral cross topology.
- Switches S 1 and S 4 lay on or symmetrically with respect to arm/axis 402 and switches S 2 and S 3 lay on an arm/axis 404 .
- the intersection between arm/axis 402 and arm/axis 404 forms the cross portion of equilateral cross topology.
- perpendicular offsets of switches S 1 , S 4 , S 2 and S 3 (and cutouts CO 1 , CO 2 , CO 3 and CO 4 in circuit board 400 ) relative to arms/axis 402 and arm/axis 404 respectively are made such that the offsets are in either a clockwise or anti-clockwise direction.
- a 50% switching duty cycle is applied to 1 , S 2 , S 3 and S 4 such that while switches S 1 and S 4 are ON, switches S 3 and S 2 are OFF and vice versa.
- circuit board 400 and heat sink 406 are mounted vertically so that the flow of heat in heat sink 506 generated by switches S 1 , S 2 , S 3 and S 4 flows vertically by convection.
- switches S 1 , S 2 , S 3 and S 4 are such that for example; the heat in heat sink 406 from switches S 2 and S 3 does not flow near switches S 1 and S 4 and the distance between S 1 and S 4 is such that the vertical flow of heat in heat sink 406 of switches S 1 and S 4 does not affect each other.
- switches S 1 and S 4 can be offset in either a clockwise or anti-clockwise direction, so that the vertical flow of heat in heat sink 406 of switches S 1 and S 4 does not affect each other.
- perpendicular offsets of switches Si, S 4 , S 2 and S 3 relative to arms/axis 402 and arm/axis 404 respectively and the distance between switches S 1 and S 4 along arm/axis 402 and switches S 2 and S 3 along arm/axis 404 respectively are preferably chosen in order to achieve minimal electromagnetic interference (EMI), minimal impedance of circuit board 400 traces and efficient heat transfer between switches S 1 , S 2 , S 3 and S 4 and heat sink 406 .
- EMI electromagnetic interference
- Switches S 1 , S 2 , S 3 and S 4 and diodes D 1 , D 2 , D 3 and D 4 are preferably connected electrically together according to full bridge converter 20 shown in FIG. 2 a .
- Circuit board 500 is mechanically attached to heat sink 506 via a screw and pillar arrangement 510 .
- Switches S 1 , S 2 , S 3 and S 4 are mechanically and thermally attached to heat sink 506 . Cutouts CO 1 , CO 2 , CO 3 and CO 4 in circuit board 500 allow the mechanical and thermal attachment of switches S 1 , S 2 , S 3 and S 4 to heat sink 506 .
- switches S 1 , S 2 , S 3 and S 4 are based upon a fylfot cross topology.
- Switches S 1 and S 4 lay parallel to arm/axis 502 and switches S 2 and S 3 lay parallel to arm/axis 504 .
- the intersection between arm/axis 502 and arm/axis 504 form the equilateral cross portion of the fylfot cross topology.
- the hands of the fylfot cross topology are represented by dotted lines as hand 512 , hand 516 , hand 514 and hand 518 .
- Hand 512 and hand 514 represent respectively the offsets of switches S 1 and S 4 with respect to arm/axis 502 .
- switches S 1 , S 2 , S 3 and S 4 are such that for example; the vertical flow of heat from switch S 2 does not significantly run into the vertical heat flow of switch S 1 , the vertical flow of heat from switch S 1 does not significantly run into the vertical heat flow of switch S 4 and the vertical flow of heat from switch S 4 does not run significantly into the vertical heat flow of switch S 3 .
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Abstract
A circuit board adapted for use in an switching converter for connecting a plurality of switches including a first switch, a second switch, a third switch and a fourth switch. The circuit board has a layout for connecting the switches. The layout is adapted for locating the switches substantially at or symmetrically with respect to the endpoints of a right-angle cross. The right-angle cross is formed from two line segments intersecting with a ninety degree angle. The circuit board may offsets the switches perpendicularly to the line segments at the endpoints of the line segments either in a clockwise or a counterclockwise direction.
Description
- The present application is a continuation of co-pending U.S. application Ser. No. 12/483,933 filed Jun. 12, 2009, which claims benefit from US provisional application 61/060878 filed on Jun. 12, 2008 by the present inventors, the entire contents of which are incorporated by reference.
- 1. Technical Field
- The present invention relates to switching converters and to specifically a circuit layout of four switches
- 2. Description Of Related Art
- The thermal resistance of materials used to package electronic components is of great interest to electronic engineers, because most electrical components generate heat and need to be cooled. Electronic components need to be cooled to avoid premature aging and consequent failure. Also, effective cooling of the electronic component(s) susceptible to generating heat in a circuit allows for a stable, efficient and predictable performance of the circuit. In particular, heat generated from electronic components in power supply/conversion circuits are mostly derived from the main switching devices.
- Heat sinks function by efficiently transferring thermal energy or heat from a first object at a relatively high temperature to a second object or the environment at a lower temperature with a much greater heat capacity. This rapid transfer of thermal energy quickly brings the first object into thermal equilibrium with the second object or environment, lowering the temperature of the first object thus fulfilling the role of a heat sink as a cooling device.
-
FIGS. 1 a and 1 b show a plan and side view respectively of acircuit board 100 withheat sink 102 according to conventional art. Fourswitches 104 are shown.Switches 104 are electrically connected tocircuit board 100 vialegs 106.Plate 104 a is used to mechanically attachswitch 104 to heatsink 102 using threadedscrew 108. An application of a heat sink compound (typically made from zinc oxide in a silicone base) is applied betweenplate 104 a andheat sink 102 prior to fastening with threadedscrew 108. The heat sink compound allows for better heat transfer fromswitch 104 andheat sink 102 to allow for the uneven surfaces of eitherplate 104 a orheat sink 102. Typicallyswitch 104 is a semiconductor switch such as a metal oxide semi-conductor field effect transistor (MOSFET) or insulated gate bipolar junction transistor (IGBJT). -
FIG. 2 a shows a conventionalfull bridge converter 20. Full bridge DC to DC converter has four main switches S1, S2, S3 and S4 connected together in a full bridge configuration. Switches S1, S2, S3 and S4 are insulated gate bipolar transistors. The collectors of switch S1 and switch S3 are connected together at node Y1 and the emitters of switch S2 and switch S4 are connected together at node Y2. The emitter of switch S1 is connected to the collector of switch S2 and the emitter of switch S3 is connected to the collector of switch S4. Each of the four main switches (S1, S2, S3 and S4) has respective diode shunts (D1, D2, D3 and D4) connected in parallel thereto. The diodes placed across switches S1 and S2 are in both the same direction similarly the diodes of switch S3 and switch S4 are both in the same direction. In the case where full bridge converter 50 is operated as a DC-to-DC converter all diodes (D1, D2, D3 and D4) connected across switches S1, S2, S3 and S4 are reverse biased with respect to the input voltage Vin. An input voltage (Vin) offull bridge converter 20 is connected across the node (Y2) between switches S2 and S4 and an input voltage (Vin +) is connected at the node (Y1) between switches S1 and S3. An output voltage (Vout −) offull bridge converter 20 is connected across the node (X1) between switches S1 and S2 and output voltage Vout+ is connected at the node (X2) between switches S3 and S4. Switching offull bridge converter 20 is typically a 50% duty cycle such that while switches S1 and S4 are ON, switches S3 and S2 are OFF and vice versa. -
FIG. 2 b shows a typical conventional buck-boost DC-to-DC converter circuit 22. The buck circuit of buck-boost DC-to-DC converter 22 has an input voltage Vin with an input capacitor C1 connected in parallel across Vin. Two switches are implemented as field effect transistors (FET) with integral diodes: a high side buck switch Q1 and a low side buck switch Q2 connected in series by connecting the source of Q1 to the drain of Q2. The drain of Q1 and the source of Q2 are connected parallel across an input capacitor C1. A node is formed between switches Q1 and Q2 to which one end of aninductor 206 is connected. The other end ofinductor 206 is connected to the boost circuit of buck-boost DC-to-DC converter 22 at a second connecting two switches: a high side boost switch Q4 and a low side boost switch Q3 together in series where the source of Q4 connects to the drain of Q3 to form node B. The drain of Q4 and the source of Q3 connect across an output capacitor C2 to produce the output voltage Vout of buck-boost DC-to-DC converter 22. - At higher switching frequencies of switched inverters/converters, lower values of reactive components can be used in circuit to achieve the required output characteristics of the inverters/converters. However, the increase in frequency can have the undesirable effect of increasing electromagnetic interference (EMI) if good circuit design and good circuit layout practices are not followed. Remembering that currents flowing in a closed path, i.e. a loop (formed by circuit board traces) acts as an efficient radiator of electromagnetic energy, maximum radiation efficiency occurs when the loop dimension is on the order of one-half wavelength. To minimize the radiation efficiency, that is to reduce radiated noise, the loop is made as physically small as possible by being aware of parasitic inductances in the board traces. High-frequency currents follow the path of least impedance (and not the path of least resistance) and a way to reduce the inductive impedance (XL=2πfL) of parasitic inductances (L) is to reduce the frequency (f) or to reduce the size of the loop, since a longer loop gives more parasitic inductance (L). Power loss (P) in the loop is the product of the inductive impedance (XL) squared and the high frequency current in the loop.
- Both static and dynamic power losses occur in any switching inverter/converter. Static power losses include I2R (conduction) losses in the wires or PCB traces, as well as in the switches and inductor, as in any electrical circuit. Dynamic power losses occur as a result of switching, such as the charging and discharging of the switch gate, and are proportional to the switching frequency.
- According to an embodiment of the present invention there is provided a circuit board adapted for use in an inverter for connecting a plurality of switches including a first switch, a second switch, a third switch and a fourth switch. The circuit board has a layout for connecting the switches. The layout is adapted for locating the switches substantially at the endpoints of an equilateral cross. The layout is adapted for locating the switches substantially symmetrically with respect to the endpoints of the equilateral cross. The equilateral cross is formed from two line segments of equal length intersecting at their centers with a ninety degree angle. The circuit board offsets all the switches perpendicularly to the line segments at the endpoints of the line segments either in a clockwise or an anticlockwise direction. The layout typically includes a respective cutout for the switches. The switches are typically chassis mounted.
- According to yet another embodiment of the present invention there is provided an inverter having multiple switches including a first switch, a second switch, a third switch and a fourth switch. A circuit board has a layout for connecting the switches. The layout locates the switches substantially at the endpoints of an equilateral cross or substantially symmetrically with respect to the endpoints of the equilateral cross. The switches are interconnected in a full bridge switching topology. The switches are interconnected in a buck-boost switching topology. A heat-sink is operatively attached to the switches for conducting heat from the switches. The switches are preferably insulated gate bipolar junction transistors (IGBT). The layout includes cutouts for the switches, having a chassis mounting for the insulated gate bipolar junction transistors; and a heat sink attached to the transistors and the chassis. The equilateral cross is formed from two line segments of equal length intersecting at their centers with a ninety degree angle. The circuit board may offset the switches perpendicularly to the line segments at the endpoints of the line segments either in a clockwise or an anticlockwise direction, thereby forming the layout of the switches in the shape of a fylfot cross. The first switch and the third switch are at the endpoints of the first line segment forming a first pair of the switches and the second switch and the fourth switch are at the endpoints of the second line segment forming a second pair of the switches. The inverter switches alternately the first pair of switches and the second pair of switches. The equilateral cross is formed from two line segments of equal length intersecting at their centers with a ninety degree angle. The circuit board may offset only two of the switches perpendicularly to one of the line segments at the endpoints of the one line segment either in a clockwise or an anticlockwise direction. The inverter is mounted vertically so that the one line segment is substantially vertical and one of the two switches is substantially below the second of the two switches so that while the inverter is operating, the heat from the lower of the two switches does not flow near the upper of the two switches. The first switch, the second switch, the third switch and the fourth switch may include: silicon controlled rectifier (SCR), insulated gate bipolar junction transistor (IGBT), bipolar junction transistor (BJT), field effect transistor (FET), junction field effect transistor (JFET), switching diode, electrical relay, reed relay, solid state relay, insulated gate field effect transistor (IGFET), diode for alternating current (DIAC), and/or triode for alternating current TRIAC.
- The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
-
FIG. 1 a and 1 b show a plan and side view of a circuit board with heat sink according to conventional art. -
FIG. 1 b shows a plan and side view of the circuit board withheat sink 102 shown inFIG. 1 a according to conventional art. -
FIG. 2 a shows a conventional full bridge converter according to conventional art. -
FIG. 2 b shows a typical conventional buck-boost DC-to-DC converter circuit according to conventional art. -
FIG. 3 a shows an equilateral cross topology according to an exemplary embodiment of the present invention. -
FIG. 3 b shows a fylfot cross topology according to an exemplary embodiment of the present invention. -
FIG. 3 c shows another fylfot cross topology according to an exemplary embodiment of the present invention. -
FIGS. 4 a shows a plan view of a circuit board and heat sink according to an exemplary embodiment of the present invention. -
FIG. 4 b which shows the side view of the circuit board and heat sink shown inFIG. 4 a according to an exemplary embodiment of the present invention. -
FIGS. 5 a shows a plan view of a circuit board and heat sink according to another exemplary embodiment of the present invention. -
FIG. 5 b which shows the side view of the circuit board and heat sink shown inFIG. 5 a according to an exemplary embodiment of the present invention. - The foregoing and/or other aspects will become apparent from the following detailed description when considered in conjunction with the accompanying drawing figures.
- Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
- By way of introduction, an intention of embodiments of the present invention is to minimize the lengths of the conductors between switches of a switching converter/inverter, minimizing interference due to parasitic capacitance and inductance, reducing electro-magnetic interference (EMI) emissions and thereby maximizing the efficiency of the switching converter.
- It should be noted, that although the discussion herein relates to switching topology for a four insulated gate bipolar junction transistors (IGBT) full bridge inverter, the present invention may, by non-limiting example, alternatively be configured as well using other types of DC-DC converters AC-DC inverters including buck, boost, buck-boost full bridge topologies with 4 switch topologies for both power supply and regulation applications.
- Before explaining embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of design and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
- The term “switch” as used herein refers to any type of switch known in the art of electronics switches such as silicon controlled rectifier (SCR), insulated gate bipolar junction transistor (IGBT), metal oxide semi-conductor field effect transistor (MOSFET), bipolar junction transistor (BJT), field effect transistor (FET), junction field effect transistor (JFET), switching diode, electrical relay, reed relay, solid state relay, insulated gate field effect transistor (IGFET), DIAC, and TRIAC.
- The term “switching converter” as used herein applies to power converters, AC-to-DC converters, DC-to-AC inverters, buck converters, boost converters, buck-boost converters, full-bridge converters or any other type of electrical power conversion/inversion known in the art.
- With reference to
FIG. 3 a an “equilateral cross” as used herein is a cross of two line segments (arm 36 and arm 34) of equal length at their center points 30 at right angles. - With reference to
FIGS. 3 b and 3 c the term “fylfot cross” as used herein has two arms;arm 36 andarm 34 which are crossed equilaterally at apoint 32.Arm 36 at each end has ahand 300 and ahand 304 which are offset perpendicular toarm 36 in an anti-clockwise direction inFIG. 3 b.Arm 34 at each end has ahand 302 and ahand 306 which are offset perpendicular toarm 34 in an anti-clockwise direction inFIG. 3 b. InFIG. 3 c,arm 36 at each end has ahand 312 and ahand 308 which are offset perpendicular toarm 36 in a clockwise direction.Arm 34 at each end has ahand 310 and ahand 314 which are offset perpendicular toarm 34 in a clockwise direction inFIG. 3 c. - Reference is now made to
FIGS. 4 a and 4 b which show a plan and side view respectively of acircuit board 400 andheat sink 406 according to an exemplary embodiment of the present invention.Circuit board 400 has four switches S1, S2, S3 and S4 connected electrically tocircuit board 400 via leads 406.Circuit board 400 has four diodes D1, D2, D3 and D4 connected electrically to circuit board via leads 408. Switches 51, S2, S3 and S4 are preferably insulated gate bipolar junction transistors (IGBTs). Switches 51, S2, S3 and S4 and diodes D1, D2, D3 and D4 are preferably connected electrically together according tofull bridge converter 20 shown inFIG. 2 a.Circuit board 400 is mechanically attached toheat sink 406 for instance via a screw andpillar arrangement 410. Switches S1, S2, S3 and S4 are mechanically and thermally attached toheat sink 406. Cutouts CO1, CO2, CO3 and CO4 incircuit board 400 allow the mechanical and thermal attachment of switches S1, S2, S3 and S4 toheat sink 406. - The layout of switches S1, S2, S3 and S4 is based upon an equilateral cross topology with
dotted lines axis 402 and switches S2 and S3 lay on an arm/axis 404. The intersection between arm/axis 402 and arm/axis 404, forms the cross portion of equilateral cross topology. In further embodiments of the present invention, perpendicular offsets of switches S1, S4, S2 and S3 (and cutouts CO1, CO2, CO3 and CO4 in circuit board 400) relative to arms/axis 402 and arm/axis 404 respectively are made such that the offsets are in either a clockwise or anti-clockwise direction. Typically a 50% switching duty cycle is applied to 1, S2, S3 and S4 such that while switches S1 and S4 are ON, switches S3 and S2 are OFF and vice versa. Typicallycircuit board 400 andheat sink 406 are mounted vertically so that the flow of heat inheat sink 506 generated by switches S1, S2, S3 and S4 flows vertically by convection. Using the plan view ofFIG. 4 a as the vertical mounting ofcircuit board 400 andheat sink 406, layout of switches S1, S2, S3 and S4 are such that for example; the heat inheat sink 406 from switches S2 and S3 does not flow near switches S1 and S4 and the distance between S1 and S4 is such that the vertical flow of heat inheat sink 406 of switches S1 and S4 does not affect each other. Alternatively just switches S1 and S4 can be offset in either a clockwise or anti-clockwise direction, so that the vertical flow of heat inheat sink 406 of switches S1 and S4 does not affect each other. - In a typical computer aided design/simulation of
circuit board 400; perpendicular offsets of switches Si, S4, S2 and S3 relative to arms/axis 402 and arm/axis 404 respectively and the distance between switches S1 and S4 along arm/axis 402 and switches S2 and S3 along arm/axis 404 respectively, are preferably chosen in order to achieve minimal electromagnetic interference (EMI), minimal impedance ofcircuit board 400 traces and efficient heat transfer between switches S1, S2, S3 and S4 andheat sink 406. - Reference is now made to
FIGS. 5 a and 5 b which show a plan and side view respectively of acircuit board 500 andheat sink 506 according to an exemplary embodiment of the present invention.Circuit board 500 has four switches S1, S2, S3 and S4 connected electrically tocircuit board 500 via leads 506.Circuit board 500 has four diodes D1, D2, D3 and D4 connected electrically to circuit board via leads 508. Switches S1, S2, S3 and S4 are preferably insulated gate bipolar junction transistors (IGBTs). Switches S1, S2, S3 and S4 and diodes D1, D2, D3 and D4 are preferably connected electrically together according tofull bridge converter 20 shown inFIG. 2 a.Circuit board 500 is mechanically attached toheat sink 506 via a screw andpillar arrangement 510. Switches S1, S2, S3 and S4 are mechanically and thermally attached toheat sink 506. Cutouts CO1, CO2, CO3 and CO4 incircuit board 500 allow the mechanical and thermal attachment of switches S1, S2, S3 and S4 toheat sink 506. - Referring again to
FIG. 5 a, the layout of switches S1, S2, S3 and S4 is based upon a fylfot cross topology. Switches S1 and S4 lay parallel to arm/axis 502 and switches S2 and S3 lay parallel to arm/axis 504. The intersection between arm/axis 502 and arm/axis 504, form the equilateral cross portion of the fylfot cross topology. The hands of the fylfot cross topology are represented by dotted lines ashand 512,hand 516,hand 514 andhand 518.Hand 512 andhand 514 represent respectively the offsets of switches S1 and S4 with respect to arm/axis 502.Hand 516 andhand 518 represent respectively the offsets of switches S2 and S3 with respect to arm/axis 504. InFIG. 5 ahand 512,hand 516,hand 514 andhand 518 are offset from axis/arms hand 512,hand 516,hand 514 andhand 518 may be offset from axis/arms circuit board 500 andheat sink 506 are mounted vertically so that the flow of heat inheat sink 506 generated by switches S1, S2, S3 and S4 flows vertically by convection. Using the plan view ofFIG. 5 a as an example of vertically mountingcircuit board 500 andheat sink 506, the layout of switches S1, S2, S3 and S4 are such that for example; the vertical flow of heat from switch S2 does not significantly run into the vertical heat flow of switch S1, the vertical flow of heat from switch S1 does not significantly run into the vertical heat flow of switch S4 and the vertical flow of heat from switch S4 does not run significantly into the vertical heat flow of switch S3. - The definite articles “a”, “an” is used herein, such as “a switch converter”, “a switch” have the meaning of “one or more” that is “one or more switch converters” or “one or more switches”.
- Although selected embodiments of the present invention have been shown and described, it is to be understood the present invention is not limited to the described embodiments.
- Instead, it is to be appreciated that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and the equivalents thereof.
Claims (15)
1. A circuit board adapted for use in a switching converter for connecting a plurality of switches including a first switch, a second switch, a third switch and a fourth switch, wherein the circuit board comprises:
a layout for connecting said switches,
wherein said layout is adapted for locating said switches substantially at the endpoints of a right-angle cross.
2. The circuit board of claim 1 , wherein said layout is adapted for locating said switches substantially symmetrically with respect to the endpoints of said right-angle cross.
3. The circuit board of claim 1 , wherein said right-angle cross is formed from two line segments intersecting with a ninety degree angle, wherein the circuit board offsets all said switches perpendicularly to said line segments at the endpoints of the line segments either in a clockwise or a counterclockwise direction.
4. The circuit board of claim 1 , wherein said layout includes a respective cutout for said switches wherein said switches are chassis mounted.
5. A switching converter comprising:
a plurality of switches including a first switch, a second switch, a third switch and a fourth switch;
a circuit board having a layout for connecting said switches,
wherein said layout locates said switches substantially at the endpoints of a right-angle cross.
6. The switching converter of claim 5 , wherein said layout is adapted for locating said switches substantially symmetrically with respect to the endpoints of said right-angle cross.
7. The switching converter of claim 5 , wherein said switches are interconnected in a full bridge switching topology.
8. The switching converter of claim 5 , wherein said switches are interconnected in a buck-boost switching topology.
9. The switching converter of claim 5 , further comprising a heat-sink operatively attached to said switches for conducting heat from said switches.
10. The switching converter of claim 5 , wherein said first switch, said second switch, said third switch and said fourth switch are selected from the group consisting of: a silicon controlled rectifier (SCR), an insulated gate bipolar junction transistor (IGBT), a bipolar junction transistor (BJT), a field effect transistor (FET), a junction field effect transistor (JFET), a switching diode, an electrical relay, a reed relay, a solid state relay, an insulated gate field effect transistor (IGFET), a diode for alternating current (DIAC), and a triode for alternating current (TRIAC).
11. The switching converter of claim 5 , wherein said switches are insulated gate bipolar junction transistors (IGBT), wherein said layout includes cutouts for said switches, the converter further comprising:
a chassis mounting said insulated gate bipolar junction transistors; and
a heat sink attached to said transistors and said chassis.
12. The switching converter of claim 5 , wherein said right-angle cross is formed from two line segments intersecting with a ninety degree angle, wherein the circuit board offsets all said switches perpendicularly to said line segments at the endpoints of the line segments either in a clockwise or a counterclockwise direction, thereby forming said layout of said switches in the shape of a fylfot cross.
13. The switching converter of claim 5 , wherein said right-angle cross is formed from two line segments, including a first line segment and a second line segment intersecting with a ninety degree angle, wherein said first switch and said third switch are at the endpoints of said first line segment forming a first pair of said switches and said second switch and said fourth switch are at the endpoints of said second line segment forming a second pair of said switches, and wherein the switching converter switches alternately said first pair of switches and said second pair of switches.
14. The switching converter of claim 5 , wherein said right-angle cross is formed from two line segments intersecting with a ninety degree angle, wherein the circuit board offsets two of said switches perpendicularly to one of said line segments at the endpoints of said one line segment either in a clockwise or a counterclockwise direction.
15. The switching converter of claim 14 , which when mounted vertically said one line segment is substantially vertical and one of said two switches is substantially below the second of said two switches so that while the switching converter is operating the heat from the lower of said two switches does not flow near the upper of said two switches.
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US14/143,699 US20140185245A1 (en) | 2008-06-12 | 2013-12-30 | Switching circuit layout with heatsink |
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US8630098B2 (en) | 2014-01-14 |
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