Radiation-Tolerant, High-Voltage Bidirectional DC-DC Converter PMIC

Alphacore proposes the integration of a 10kW, 100V to 5000V bidirectional DC-DC PMIC controller. A multi-chip package (MCP) approach to integration, in conjunction with inductive isolation, yields a single PMIC controller with tremendous savings in space and cost. The PMIC in combination with external WBG FETs implements a dual active bridge (DAB), bidirectional DC-DC converter module that can draw energy from the photovoltaic panel or the battery or, in combination with an inverter, from the grid. Alternatively, it can efficiently charge the battery or deliver energy to the loads when necessary. The PMIC can be part of a DC system or an AC grid. One of the topologies capable to implement seamlessly a unidirectional or bidirectional power flow is the digitally controlled DAB converter, whose phase shift sign determines the direction of the energy flow. DAB has the electrical advantages of wide voltage operation range, zero voltage switching via resonant transition of all devices, low switching and conduction losses, minimum device voltage stresses, and easier bidirectional control. The DAB also has favorable magnetics trade-offs: well-utilized transformer core, low transformer losses, and small series inductor sustaining low volt-seconds. Exceptionally high efficiencies have been demonstrated for this architecture. In Phase I, Alphacore successfully designed and simulated the PMIC controller, as well as the DC-DC converter module. Critical system building blocks (LDO, BGR and flyback converter) have been already fabricated and were tested in a Cobalt 60 chamber, showing the effectiveness of the implemented radiation hardening techniques. This test data lowers the risk of the proposed Phase II program. In response to the NASA SBIR topic Z1.05-1 “Radiation-Tolerant, High-Voltage Converters for Lunar and Mars Missions”, Alphacore Inc. will develop a 10kW, 100-Vdc to 5,000-Vdc radiation-tolerant, fully bidirectional, high-voltage, high-gain, lightweight, high-efficiency, DC-DC converter based on a mixed-signal (analog/digital) power management integrated circuit (PMIC) driving external Wide Band Gap (WBG) gallium nitride (GaN) and silicon carbide (SiC) field effect transistors (FETs) and passive components (inductors, transformers, capacitors, resistors).  The developed PMIC will have a reduced component count, enabling reduced failure modes, and smaller area occupancy of PCB (printed circuit board).  It will include over-voltage protection, fault tolerance, load monitoring, as well as allow control and status monitoring by a remote power system controller. This PMIC includes all controller circuitry and drivers integrated in a single package and drives an external WBG-based power stage.   Objective 1: PMIC dies design, layout and fabrication The Alphacore PMIC is an MCP/SiP device including 4 hi-side and 2 low-side  driver/controller chips (sextuplet made 2 identical SiC driver ICs (SD), 2 identical GaN driver ICs (GD) and 2 low voltage ICs (SIC, GIC ). For each of the 4 unique chips, Alphacore will review and complete the circuit level simulations performed in phase I and proceed to layout and fabrication.  Objective 2: Characterize Alphacore’s PMIC silicon chips The 4 individually packaged chips will be evaluated for 1) overall functionality evaluations, 2) tests to measure and assess performance benchmarks, 3) TID radiation effect evaluations, and 4) single event effect evaluations with heavy ions. As an intermediate step, the PMIC will be hardware-simulated with the 4 chips and associated FETs and passives mounted on a PCB.   Objective 3: PMIC packaging and characterization The PMIC controller will be implemented in SiP/MCP form and tested for electrical performance and radiation hardness.  Objective 4: Module evaluation As a final step, the module (SiP/MCP PMIC + discrete FETs and passives) in built on a PCB, implementing a 100V-to-5000V DC-DC converter. The module will be evaluated for 1) overall functionality, 2) tests to measure and assess electrical performance. Deliverables •    Quarterly reports •    Final Report  •    Five PMIC SiP/MCP samples delivered to NASA  

The low-profile, lightweight, high efficiency GaN/SiC PMIC significantly advances the robustness, reliability, and safety of the electricity infrastructure. It will benefit outer planet surface and aerial missions including missions listed in the 2023-2032 National Academies decadal survey: outer planet missions operating at extreme low temperatures (UOP, Enceladus Orbilander); future lander and rover missions on icy moons and Mars (Mars Deep Time Rover); and power management needs for missions to the lunar surface (Artemis). The target applications include high-voltage power switching and power conversion, grid power and battery chargers for  electric cars. The rise in demand for telecommunications, autonomous and electric vehicles, and industrial robots is expected to be a significant driver to commercial market segments. Alphacore’s PMIC fulfills those needs, with specifications that exceed its known competitors.

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