Power modules may be a solution to some long-standing problems in the semiconductor industry. With advanced component integration and performance improvements, modularity offers a completely new power solution, simplifying the design process.
Power modules are a relatively new technology, and some developers believe they lack flexibility, while others think they're just a passing fad. The following summarizes some common misconceptions about power modules within the industry.
1. Power modules don't save that much time. You know which components are best suited for your design.
Engineers know the pain of repeatedly sifting through various companies' datasheets, or seeing the lengthy delivery cycle of a certain component, and ultimately discovering during testing that the subsystem was only affected by a single component not being soldered correctly.
Power modules eliminate most problems. Using power modules significantly reduces the time required for component procurement and testing, allowing you to focus on addressing differentiated issues.
2. Power modules are only suitable for more general-purpose cases, while discrete solutions are always better because you can optimize them for any situation.
A fully integrated solution does not mean a completely universal solution. In fact, part of what makes power modules so easy to use is that these products are actually designed to meet specific applications. For example, power modules optimized for low noise, fast transient response, or extended operating temperatures can perform just as well as traditional discrete solutions.
Furthermore, many modules ship in pin-to-pin families that span specific output current or voltage ranges. For example, the TPSM41615 and TPSM41625 power modules are stackable 15A and 25A solutions that share the same footprint, thus covering a current range of 15 to 50A (Figure 1). Instead of being limited to some generic all-purpose solutions, you are able to select devices that fit your system requirements and avoid redesigning when changes occur.
The TPSM41615 and TPSM41625 share the exact same pinout and are stackable, allowing for greater flexibility and supporting applications up to 50 A.
3. Power modules offer no inherent advantages beyond integration, while discrete solutions can be fine-tuned by selecting different passive components as needed.
When you choose to use power modules in your design, you can rest assured that the solution you select is handcrafted by the industry's best power supply, packaging, and placement experts. In addition to datasheets, power module manufacturers provide designers with simulation tools and data. By choosing a power module, you can use a fully customized power supply, meaning you don't have to spend extra time determining if a product is right for you.
Using discrete solutions is like putting elementary school drivers in Formula One races. Why take the risk when one module guarantees a place on the podium?
4. The power module used non-compliant components.
If your power supply will be used at an altitude of 30,000 feet, you need to ensure that the temperature will not cause it to malfunction. Similarly, in an operating room, you should avoid power supply interference that could cause noise or distortion in the output of imaging equipment.
To mitigate this situation, you can use discrete converters that operate over an extended temperature range or those compliant with CISPR. However, this still requires selecting and sourcing qualified components that meet these specifications.
Fortunately, the power modules are pre-verified to meet these requirements, providing you with a plug-and-play solution out of the box. For electromagnetic interference (EMI) sensitive applications, EMI-tested power modules (such as the TPSM63606) contain integrated passive components and are laid out to meet stringent requirements.
5. Power modules are expensive.
Smaller, more efficient, and easier-to-use things are often more expensive, and thankfully, power modules are not for laptops or smartphones.
First, the price gap between power modules and discrete solutions is slowly closing. When you consider the costs of sourcing, certifying, and placing passive components already integrated into the module, it's clear that it's quite close to discrete components.
Another often overlooked factor is the potential cost of problems. Compared to the costs of recalls, recertification, retesting, etc., the "premium" associated with power modules is worthwhile.
6. Power modules will not help you save space on your circuit board.
Power modules can be smaller than discrete solutions in embedded packages. Discrete solutions place the chip directly on the PCB, creating other peripheral components, especially inductors, which also take up a lot of space.
The uSiP/SiL package employed demonstrates a high power density that cannot be achieved through discrete methods.
7. The power module is too high .
Discrete solutions themselves almost never cause a significant increase in solution height. In fact, most increases in height are actually caused by inductors, as they are almost always the tallest component in a power management system. Because power modules are typically optimized for the size, efficiency, and height of the solution, you can usually expect module heights to be the same as, or even shorter than, discrete implementations.
8. The power module is not optimized for efficiency because the power module manufacturer does not consider factors other than inductor selection.
Because inductors are pre-selected and integrated, power modules are often perceived as sacrificing efficiency for ease of use. However, power modules are actually designed to provide the most efficient solutions and offer additional integration advantages.
Since discrete efficiency curves typically depend on the switching MOSFETs, heat dissipation, and the selection of external components, overall efficiency is actually influenced by multiple factors. Power modules strive to take all external factors into account (which is difficult for the average engineer to manage) and provide the simplest solution while maintaining or exceeding your expected efficiency standards.
9. Power modules are several generations behind leading discrete solutions.
Integrated circuit (IC) manufacturers are constantly looking for ways to simplify the design and manufacturing process of electronic products. As I mentioned earlier, industry-leading discrete solutions are often the source of inspiration for the latest and best power module solutions.
However, beyond chips, IC designers are also pushing the boundaries of packaging, component placement, and process technology. The latest and most powerful features, which were typically only available through discrete converters, can now be offered in the smallest, easiest-to-use, and most efficient form.
10. You do not need a power module – you can easily replicate the power solution design yourself.
To minimize the size of a solution, adventurous designers may prefer to create the final power supply with a more compact arrangement of components to save as much board space as possible, but many of these solutions are not easy to replicate.
One example is modules that can embed components directly into the substrate where the chip resides. Another example is the secondary molding of molds and integrated components to improve their adhesion to the leadframe.
11. Power modules are just a fashion trend.
While I don't have a crystal ball, one thing is clear: as requirements become more stringent, the design challenges will only increase (and take longer to resolve). Every day, more and more power supply designers are turning to power modules because they offer reduced size, optimized efficiency, and the richest feature sets. The resulting benefits far outweigh the risks of venturing out to find the right power solution on their own.
In addition, semiconductor manufacturers constantly monitor power trends and application requirements, all in an effort to reduce the frequency of obstacles in your designs and help you bring your products to market faster than ever before.
in conclusion
You need an efficient, powerful, and easy-to-use power solution. By implementing power modules, you can effectively embed industry-leading expertise into your design. While acknowledging that there's never a one-size-fits-all power solution, I hope that after reading this article, you'll give power modules a try.
