The present invention relates to a MOSFET in which bouncing of the gate bias leading to unintentional turn-on of the device is limited or eliminated, and in particular to such a device in a push-pull stage of a converter operating in a switching mode.
Switching mode DC to DC converters are commonly used to provide conversion from one DC voltage to another at high efficiency. Improving the efficiency of such converters is an important design goal, especially where large banks of such converters are operating within the same space, such as in computer server farms. In these situations, the improvement in the efficiency of the converter not only reduces the amount of power the converter consumes, but dramatically reduces the cooling load placed upon the premises.
Methods to improve the efficiency of switching type DC to DC converters have been extensively studied. In an article entitled “The future of Discrete Power in VRM Solutions,” at the Intel Technology Symposium 2003, Jon Hancock describes the advantages that can be achieved by increasing the switching frequency, but this is limited by the switching losses of the power switches. One source of switching losses is the shoot-through current that occurs when the low-side switch is turned back on during the conduction period of the high-side switch which is caused by bouncing of the gate electrode bias of the low-side switch. He describes the components that require special attention to minimize the parasitic inductance component to reduce the dv/dt on the drain of the low-side switch MOSFET. A high dv/dt on the drain of the transistor injects charge into the gate of the low-side switching transistor via the Miller effect “Cgd”. This injected charge has to be accommodated by the Cgs capacitance before it is drained to ground through the opposite stage of the gate driver. This event is associated with a short term increase in Vgs at the gate of the switching transistor. If the amplitude of the Vgs increase is higher than the threshold voltage Vth of the MOSFET, then the switch is turned on and the large shoot-through current flows from supply rail to ground. This effect has to be avoided as it leads to significant power loss, and if repetitive, will impair the reliability of the system.
In an article entitled “DV/DT Immunity Improved Synchronous Buck Converters,” in Power Electronics Technology, July 2005, Steve Mappus describes this problem. One solution is to utilize transistors that have a higher Vth, but such transistors usually have a higher Rds,on which leads to higher conduction losses. He then goes on to describe gate driver selection. Large charge and sink currents have to be delivered by the gate drivers in order to enable fast switching of the MOSFETs. Here, not only the output of the gate driver is important, but the gate resistance and source inductance of the MOSFET have to be kept at a minimum in order to allow hard switching.
If the break-before-make delay time of the switching of the high-side and low-side transistors is long enough, there is a time period where the integral diode of the lower transistor switch conducts the free wheeling current. At the end of the delay time, the diode is commutated by the changing polarity of the voltage at the switch node and the associated reverse recovery current peak adds to the nominal current increasing switching power loss. Any power loss decreases the efficiency of the power conversion and high switching loss inhibits the aimed increase in the switching frequency.
The shoot-through problem in synchronous buck converters has also been addressed in Fairchild Semiconductor Application No. AN-6003, Apr. 25, 2003. A solution proposed here is the utilization of slowing the rise time on the high-side switching transistor. This, of course, reduces the switching efficiency of the high-side switch.
In the U.S. Pat. No. 5,744,994, issued Apr. 20, 1998, to Richard K. Williams, he describes the current flowing through the lower switching transistor under forward bias of the integral PN diode as being shared by the integral diode and the FET channel. The lower the Vth of the MOSFET, the more current flows through the channel and the charge stored in the body diode “Qrr” is less. Less Qrr means lower reverse recovery current peak and lower power loss during computation. Also, the design of the lower switching transistor device with a low Vth lowers its Rds,on value at a given drive in Vgs voltage. This in turn lowers the conduction loss in the lower switch and increases the overall converter efficiency. However, this exacerbates the shoot-through problem as discussed above.
Accordingly, there is a need to implement a power MOSFET switch with a low threshold voltage with reduced or no unintentional current flow due to a Miller effect during turn-off event.
It is a general object of the present invention to utilize a capacitive coupling between the gate and drain terminals of a power MOSFET, which is the root of the problem of unintentional turn-on of the switch, as a solution to the problem. This and other objects and features are attained in accordance with an aspect of the invention by a MOSFET device comprising a main power MOSFET having a drain, source and gate. A pull-down MOSFET has a drain connected to the gate of the main power MOSFET and a source connected to the source of the main power MOSFET. A gate of the pull-down MOSFET is connected to one terminal of a capacitor and another terminal of the capacitor is connected to the drain of the main power MOSFET, whereby dv/dt of a potential at the drain of the main power MOSFET during turn-off of the main power MOSFET causes the pull-down MOSFET to turn-on via capacitive coupling and hold the gate of the main power MOSFET during turn-off.
Another aspect of the invention includes a switching DC to DC converter with a push-pull stage having a high-side switch and a low-side switch, the low-side switch comprising a main power MOSFET having a drain, source and gate. A pull-down MOSFET has a drain connected to the gate of the main power MOSFET and a source connected to the source of the main power MOSFET. A gate of the pull-down MOSFET is connected to one terminal of a capacitor, another terminal of the capacitor is connected to the drain of the main power MOSFET, whereby dv/dt of a signal at the drain of the main power MOSFET during turn-off of the main power MOSFET causes the pull-down MOSFET to turn-on via capacitive coupling and hold the gate of the main power MOSFET at or near source potential to prevent turn-on of the main power MOSFET during turn-off.
Another aspect of the invention is provided by a method of operating a switching DC to DC converter comprising alternately turning on and off a high-side MOSFET switch and a low-side switch. When turning the low-side MOSFET switch off, utilizing the Miller effect voltage on a gate of a pull-down MOSFET to operate the pull-down MOSFET to couple a gate of the low-side MOSFET switch to a source thereof, whereby conduction in the low-side MOSFET switch during turn-off is reduced or prevented.
Yet another aspect of the invention includes a high-side switch with a main power MOSFET incorporating a pull-down FET. A pull-down MOSET has a drain connected to the gate of the main power MOSFET and a source connected to the source of the main power MOSFET. A gate of the pull-down MOSFET is connected to one terminal of a capacitor, another terminal of the capacitor is connected to the drain of the main power MOSFET, whereby dv/dt of a signal at the drain of the main power MOSFET during turn-off of the main power MOSFET causes the pull-down MOSFET to turn-on via capacitive coupling and speed-up the turn-off of the main power MOSFET. The hard turn-off of the high-side switch reduces the switching losses associated with this transistor.
An embodiment of the present invention is shown in
As shown in
In this embodiment, pull-down FET is a NMOS transistor which has an active area in the range of 0.5 to 4 percent of the activate area of the main NMOS transistor 102. In one embodiment, the coupling capacitor has a value in the range of 0.5 to 3 percent of the Cgs of the pull-down MOSFET and the resistor 120 has a value between 100 and 10 k ohms. The optional resistor 120 is attached between the gate and source terminal MOSFET 110 to stabilize the start up of the circuit and provides a reset function after the turn-on of the pull-down MOSFET.
In operation during the conduction of the main MOSFET 102, the pull-down MOSFET 110 is turned off and does not play a role. During the turn-off of the main switch MOSFET 102, the dv/dt effect across the main switch during the turn-off process, causes the coupling capacitor to pull up the gate of the pull-down MOSFET 110, turning the transistor 110 on which, in turn, holds the gate terminal 108 of the main MOSFET 102 at its source potential. The self-driven pull-down MOSFET 110 speeds up the switching of the main MOSFET during turn-off, and eliminates or dramatically reduces the unintentional bouncing at its gate terminal 108. Thus, the Miller effect, which causes the problem at the gate 108 of the main MOSFET 102, is utilized to drive the pull-down MOSFET 110 and eliminate or drastically reduce the problem. Thus, the Miller effect, which causes the problem, becomes the solution to the problem.
In an embodiment, the pull-down FET 110 can be made on a small die with an integrated coupled capacitor 118 and the resistor 120. This die can be attached to the main switch and placed into the same housing which provides the user with a three-terminal device as in the case of a conventional MOSFET. However, the pull-down FET 110 can also be supplied outside the device or can be integrated into the same die containing the main MOSFET 102.
One way to realize all of the components integrated onto the same die is shown in
In
In this embodiment, the pull-down FET is distributed across the active area of the main switch. The segments of the pull-down FET are attached to individual segments of the main FET, breaking the gate fingers in the middle. This layout assures minimum impact of the gate resistance on the switching speed of the combined transistors. The placing of the pull-down FET and the main switch FET on the same substrate in a common source technology, as taught in the co-pending application, assures a virtually zero inductance between their source terminals. The coupling capacitance can be easily integrated as insulator and metal layers running on top of the drain region of the main FET. This layout facilitates the utilization of the Miller effect to couple the pull-down FET gate and hold the pull-down FET at the source potential to eliminate or drastically reduce the shoot-through at the main switch, by placing both devices on the same die.
Another embodiment of the present invention is shown in
A gate driver circuit 306 is coupled between supply voltage VCC and ground CGND and provides the signals to the high-side and low-side switches, as well-known in the art. The gate driver circuit is triggered by a source of pulse width modulation signals PWM coupled terminal 340. The gate driver 306 provides the signals to the main switches at the gate 312 of the high-side switch and the gate 322 of the low-side switch transistors.
The implementation of such a module in a synchronous buck converter topology achieves following advantages. The low-side switch Q2 can be designed as a device with a low threshold voltage Vth. This lowers the Rds,on of the power switch for a given Vgs driving voltage. In turn, the low Vth reduces the Qrr of the integral body diode lowering switching losses. Having the integrated pull-down transistor 326 leads to a hard turn-off of the low-side switch Q2 that holds the gate thereof firmly at the source potential. This reduces switching power loss as well as drastically reducing or completely eliminating shoot-through events. This also increases the reliability of the circuit. The improved Rds,on and the switching components of the low-side switch Q2 lead to a higher efficiency for the converter.
These advantages are illustrated by the PSPICE simulations which are shown in
In
The efficiency of a converter for different cases under study is presented in
All three curves 708, 710 and 712 for the cases in which the low-side switch has the integrated pull-down FET, shows some advantages in efficiency as compared to the respective conventional case. This is due to the lower switching losses resulting from a harder turn-off of the low-side switch. Additionally, even in the case of the lowest threshold voltage of 0.8 volts (Graph 708), there is no sign of any shoot-through event. Some small decrease of efficiency with a low threshold voltage and light load conditions is due to a leakage current through the channel of the low-side main MOSFET switch during switching.
The low-side switch Q2 has a main switch MOSFET 818, having its drain 820 connected to the node 814, and thus the output 816. The gate 822 is connected to gate driver 806 to receive gate drive signals as is known in the art. The source 824 of main switch MOSFET 818 is connected to ground at terminal 834. The FET pull-down transistor 830 has its drain 828 connected to gate 822 of main switch MOSFET 818. The gate 826 of pull-down FET 830 is coupled via capacitor 836 to the drain 820 of main switch MOSFET 818. The gate 826 of pull-down FET 826 is also coupled via reset resistor 838 to the source of pull-down FET 832 and the source 824 of the main switch MOSFET 818.
The gate driver 806 is connected to a supply voltage VCC and ground VCGND and receives a PWM (Pulse Width Modulation) signal at terminal 840. Gate driver circuit generates the switching wave forms for the high-side and the low-side switch as known in the art, and need not be described in detail here. An advantage of having a pull-down FET for the high-side main MOSFET switch is that it provides a sharp turn-off of the high-side main switch, which cuts switching losses. It allows the use of transistors with a low threshold Vth and can possibly cut the dead time between the operation of the high-side main MOSFET switch and the low-side main MOSFET switch at the fall edge of the duty cycle.
Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made thereto without departing from the spirit and scope of the invention as defined by the appended claims. For example, the present invention can be advantageously manufactured in accordance with the teachings of U.S. Pat. No. 7,282,765 to reduce the gate drive requirement, which is incorporated herein in its entirety by reference.
This application is a nonprovisional of U.S. Provisional Application Ser. No. 61/289,551, filed Dec. 23, 2009 and is related to commonly-owned, co-pending application Ser. No. ______ (TI-67872), entitled “Integration of MOSFETS in a Source-Down Configuration,” filed on even date, which is a nonprovisional of U.S. Provisional Application Ser. No. 61/289,516, the contents of which are incorporated herein by reference in its entirety.
Number | Date | Country | |
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61289551 | Dec 2009 | US |