Space Qualified, High Efficiency, High Current, Modular Power Converter Using Multi-Layer High Density Packaging

VPT proposes to design an innovative high-efficiency, low voltage power converter using new radiation resistant silicon synchronous rectifiers. To meet the demanding performance requirements, a high frequency, multi-module, phase interleaved, approach will be employed. The design will also incorporate several VPT-developed technologies. These include a new integrated magnetic power circuit topology, a technique for reliably self-driving synchronous rectifiers, a new feedback control technique, and a multi-layer hybrid packaging technique. VPT's integrated magnetic circuit minimizes the number of interconnects on the transformer secondary and was specifically developed for low voltage, high current applications. The self-driven synchronous rectifier approach recovers energy stored in the device capacitance, yet unlike prior art, allows reliable parallel module operation down to very low output voltages. The feedback control technique allows high bandwidth performance with complete isolation yet does not use an opto-coupler. To achieve high density packaging, a multi-layer hybrid construction technique will be compared against surface mount technology. The converter will be compatible with the requirements of several popular new high-voltage regulated satellite buses including Space Systems Loral, +100Vdc, Hughes, +50Vdc, and Lockheed-Martin, +70Vdc.