Multi-phase distributed-output power converters

An apparatus comprising:

• a switching power converter including a transformer including a magnetically permeable core structure, the power converter including a multi-layer printed circuit board having a plurality of conductive layers and a plurality of insulation layers, and each conductive layer being separated from one or more adjacent conductive layers by one or more respective insulation layers;
• the transformer including at least one primary winding and a plurality of secondary windings formed in one or more of the conductive layers in the printed circuit board, the secondary windings being magnetically coupled to the at least one primary winding through the magnetically permeable core structure;
• a plurality of self-controlled semiconductor switching devices electrically connected to selectively connect a respective secondary winding to an output terminal, each self-controlled semiconductor switching device including internal circuitry configured to control turning ON and OFF of one or more switches within the device based upon signals at terminals of the respective one or more switches;
• a first package, including the magnetically permeable core structure, encapsulating the printed circuit board and the plurality of self-controlled semiconductor switching devices mounted to the printed circuit board, the first package including a cured magnetically-permeable encapsulation compound having a relative magnetic permeability of at least 10;
• the PCB being free of control signals;
• and
• a driver circuit, external to the first package including one or more power switches and a switch controller configured and arranged to operate the power switches to drive the at least one primary winding in a series of converter operating cycles during which power is converted from an input to the driver via the primary and secondary windings for delivery to the output terminal.

An apparatus comprising:

• a switching power converter comprising:
• a multi-layer printed circuit board (“PCB”) including a plurality of conductive layers and a plurality of insulation layers, each conductive layer being separated from one or more adjacent conductive layers by one or more respective insulation layers;
• wherein the multi-layer printed circuit board defines a plurality of core leg apertures;
• a magnetically permeable core structure comprising magnetically-permeable encapsulation compound that encapsulates at least a portion of the multi-layer printed circuit board and fills in the core leg apertures,
• wherein the magnetically permeable core structure includes magnetic paths that pass through the conductive layers in at least two leg locations;
• at least one main winding formed in one or more of the conductive layers;
• a plurality of winding elements formed in the conductive layers;
• and
• a plurality of converter cell elements, each including a switch and a respective winding element, the converter cell elements being physically arranged in a step and repeat pattern, in a plurality of groups, the winding elements in each group of cell elements being arranged to overlap a respective main winding;
• wherein the respective winding element associated with each cell element has a first end connected to a terminal of the switch in the cell element and a second end connected to an output terminal.

An apparatus comprising:

• a multi-layer printed circuit board (“PCB”) including a plurality of conductive layers and a plurality of insulation layers, each conductive layer being separated from one or more adjacent conductive layers by one or more respective insulation layers, in which the printed circuit board has a top surface and a bottom surface;
• wherein the multi-layer printed circuit board defines a plurality of core leg apertures;
• at least one main winding formed in one or more of the conductive layers;
• a plurality of winding elements formed in the conductive layers, in which portions of the winding elements are arranged to overlap respective portions of the at least one main winding;
• at least one electronic component disposed on at least one of the top surface or the bottom surface of the printed circuit board;
• a magnetically-permeable core structure comprising a cured magnetically-permeable encapsulation compound that encapsulates at least a portion of the multi-layer printed circuit board and fills in core leg apertures;
• wherein the magnetically-permeable core structure includes magnetic paths that pass through the conductive layers in at least two leg locations;
• wherein the at least one electronic component is configured to enhance stability of the printed circuit board when the printed circuit board is disposed in a mold cavity during an encapsulation process in which a magnetically-permeable encapsulation compound is injected into the mold cavity to cause the printed circuit board to be encapsulated by the magnetically-permeable encapsulation compound.