This invention introduces an advanced four-pillar matrix transformer architecture that doubles magnetizing inductance, reduces core volume, and minimizes circulating currents for compact, high-efficiency 48 V-to-sub-1 V conversion. Its optimized diagonal core geometry and parallel winding design improve thermal balance and efficiency, enabling scalable single-stage power modules for CPUs, GPUs, and data-center systems.
Background: High-performance computing and data-center systems require efficient delivery of high currents from 48 V distribution lines to sub-1 V CPU and GPU rails. Traditional step-down transformer converters face challenges of high leakage inductance, large core sizes, poor current sharing, and high switching losses. Attempts to increase inductance often worsen power loss or bulk. Two-stage topologies add cost and complexity, while existing core geometries impose trade-offs between magnetic performance and miniaturization. An improved, compact transformer design is needed to achieve high power density and conversion efficiency in modern computing and telecom applications.
Technology Overview: This invention employs a four-pillar E-E matrix transformer architecture in which primary windings are connected in series and secondary windings in parallel. Each pillar couples flux only with one adjacent limb, effectively doubling magnetizing inductance (from 16/R to 32/R) without increasing turns or core height. A novel diagonal, hollowed-out core geometry reduces volume per the relation V_red = h(8W_D² + 4.686D_PW_D – 1.313D_P²), maintaining flux density and mechanical strength while minimizing core loss. The structure reduces leakage inductance and AC resistance, enhances thermal uniformity, and improves current sharing across secondary outputs. The result is a compact, efficient transformer ideal for direct 48 V-to-sub-1 V single-stage power conversion.
Advantages: • Doubles magnetizing inductance without increasing turns or height, reducing circulating current and boosting efficiency • Reduces core volume through diagonal pillar geometry while preserving flux density and structural integrity • Lowers core losses via optimized magnetic path and reduced volume • Minimizes leakage inductance and AC resistance with parallel secondary windings • Simplifies synchronous rectification timing, eliminating zero-current detection circuits • Reduces switching losses and device stress versus conventional matrix transformers • Improves thermal balance and secondary current sharing • Enables single-stage 48 V-to-sub-1 V power conversion for high-density modules
Applications: • 48 V-to-sub-1 V voltage regulator modules for data-center CPUs and GPUs • High-current isolated DC-DC converters for telecom and networking systems • 48 V isolated power modules for 5G radio heads and base stations • Automotive 48 V-to-1.2 V converters for ADAS, AI, and sensor systems • Industrial automation and control systems needing compact high step-down converters
Intellectual Property Summary: • United States – 63/485,229 – Provisional – Filed 02/15/2023 – Converted • United States – 18/442,000 – Utility – Filed 02/14/2024 – Published as US 2024-0296991 A1 – Status: Filed
Stage of Development: Prototype tested under 48 V input.
Licensing Status: This technology is available for licensing.
Licensing Potential: Well-suited for power electronics manufacturers, data-center infrastructure suppliers, and semiconductor power module developers seeking compact, high-efficiency transformer solutions for next-generation computing, telecom, and automotive systems.
Additional Information: Prototype test data and magnetic field simulations demonstrating inductance gain and efficiency improvements available upon request.
Inventors: Pritam Das, Tuhin Sasmal