A 12- or 48-V Input, 0.9-V Output Active-Clamp Forward Converter Power Block for Servers and Datacenters

DC-to-DC power supplies are critical components for processors in high performance computing and datacenter servers. Conversion from an intermediate bus voltage (e.g., 12 or 48 V) to the core voltage (∼0.9 V) of processors must be efficient, compact, and cost effective. This paper proposes two versions of active-clamp forward converter (ACFC) power blocks to supply core voltage from either 12 or 48 V intermediate bus voltage. The ACFC power block can be individually tested prior to assembly and vertically soldered onto the motherboard to fit in a standard 1U server. A low loss, compact planar transformer is designed into the ACFC power block printed circuit board (PCB). A custom, standing slab inductor not only provides high inductance and high saturation current but also helps to mechanically support the power block. A one-piece copper winding connects the transformer to the inductor, thereby reducing the dc loss in the current path. Thorough analysis is performed to model the conversion loss of the proposed power block. Experimental results show a peak efficiency of 90.4% (12 V input) and 89.5% (48 V input) with 0.9-V output.