Heterogeneous Integration in Switchmode Electronics

This dissertation looks closely at deployment of thin-film integrated inductors within power electronics, including details on the state-of-the-art technology for such inductors and related packaging techniques. Design challenges for systems using these inductors are discussed in detail, including the current outlook on magnetics development and the impact of these non-linearities on system design. In particular, this work looks closely at effects often left behind in modern discrete-component-based power module design, such as soft core saturation and significant high-frequency losses. In conjunction with the magnetics, a well-known non-linear controller for buck converters is analyzed in-depth for the first time, using frameworks from variable structure and sliding-mode control. This allows for development of a more profound rationale for the heuristic design guidelines that have been heretofore provided for this class of controllers. To verify the theoretical development, a testbench integrated CMOS front-end for a switched-inductor step-down, or buck converter is used to investigate departures of system behavior from the general wisdom around buck converter performance. Two packaging methodologies are explored for integration, and their impact on the design cycle and module lifetimes are discussed in some detail.