DC-DC converter construction techniques

A quick look at some interesting construction techniques used in DC-DC converter modules

[AppliedScience]

I didn't know how small DC converters could be. Wow!

[jcims]

I'm always impressed by the resolution of the X-ray imagery.  What a handy tool to have!

Very neat vid, thanks for putting it together!

[Stormy_-]

I think you have said "isolation" at least 50 times... nice video! This is an ingenious solution they have come up with.

[jasongladen]

@11:42 maybe it avoids a bunch of plunge cuts for the tool path?

[superdau]

Maybe the gap in the stack is for insertion of the ferrite, so some automated grippers can place it?

[jjoster]

They may use a liquid PCB process. Basically, they use epoxy rather than prepreg. That would allow them to do a flip chip package and then encapsulate rather easily. I had a 36oz PCB manufactured for me using that process once.

[LEDtest]

The holes in the sides could have multiple purposes. 1) Like Mike said in the video, to allow for outgassing 2) To generally allow pressure equalization (which sort of includes Nr1). If there are no holes, it's basically an air bubble, which will expand/contract with temperature and might cause damage to the brick 3) As many of you wrote, it's probably faster in production.

[DanielPCline]

I think the holes in the sides are simply to facilitate routing out many at one time... runs up does a circle.. runs up... does a circle... etc etc. it doesn't effect performance and makes it easier to rout many

[krawutzimon]

I think the gaps in the side of the murata package are to allow expanding air to escape when it is heated by the ferrite.

[RODALCO]

Great video. Very interesting, very high current output for such small packages.

[Lion_McLionhead]

So this is what happens when Dave rants about the kind of boost converter that would fit in a AA battery extender.

[arcadeuk]

Very interesting video Mike, thanks for sharing. BTW those nano power modules go up to 2amps in the range!

[Serostern]

I think the reason for the slot 11:25 might be that you don't need to lift the router.
A XY machine is cheaper than a XYZ machine?

[Kilohercas]

Most extreme packaging is XCL214, or similar type, they put inductor around chip. Very small, and no parts needed ( well, capacitor). Used in my resent design, works great :)

[skweek]

Did you take those x-rays on the baggage scanner? :)

[gamerpaddy]

next big "small" thing would be to fit the inductor into the die, or the die into the inductor package.

[nixie]

Awesome video! I always learn something when you post ^^

[WizzRacing]

I need to build one of these for 12v HT motor. Now I know where to start.

[nickguy]

I don't see the point of that last one -- the TI.  You have to add external caps and resistors, so the only thing they're really providing is 3D placement of an IC and inductor.

If saving space is the driver, you could achieve the same by placing the IC on the bottom of the PCB.  If build cost or complexity doesn't allow you to load both sides of the board, placing them side-by-side only takes an extra 5mm^2 of PCB space.  This seems to fit the niche where you can't get away with either.  I guess that's something, but... not much.  Especially since you have to deal with that weird package, and subsidizing the cost of a lower-volume solution (compared to bare driver ICs.)

Is there something else I'm missing maybe?

[aserta]

Very interesting episode. So many details :)