SBIR-STTR Award

Alphacore will design, fabricate and test a buck DC-DC converter that can directly convert voltages from 5V – 12V down to 900mV, while supporting at least 10A of current to the load. Our goal is 20A load current, a requirement for some of the most powerful FPGAs. The output voltage will be settable between 900mW and 3.3V. In this Phase I program, we will design a digitally controlled, high-efficiency, radiation hard, hybrid GaN/CMOS integrated single module SIMO DC-DC converter to meet these specifications. The developed converter will have a reduced component count, enabling reduced failure modes, lower PCB area and it includes over voltage protection, fault tolerance, load monitoring, and allows control and status monitoring by a remote power system controller. This solution includes all controller circuitry and drivers integrated in a single CMOS ASIC chip, as well as the GaN-based DC-DC converter’s power stage. The hybrid module will have a very small form factor, namely 20mm x 20mm x 6mm. Alphacore’s SIMO POL converter will utilize CMOS based drivers and controllers for the GaN power stage. The driver and controller would be based on X-FAB’s latest XT018 process, a 0.18 µm modular high-voltage SOI technology. It combines the benefit of conventional SOI wafers with Deep Trench Isolation (DTI), those of a state-of-the-art six metal layers 0.18 µm process, and localized partial SOI for unique high-voltage super-junction (SJ) power transistors. Unlike traditional high-voltage LDMOS devices from conventional bulk or SOI CMOS processes, the unique high-voltage SJ DMOS power transistors with VDS breakdown voltage of 100V, 140V and 200V offered in XT018 have reduced conduction loss with the same silicon area, such that lower FOM is available for higher efficiency applications. The planar high-voltage SJ DMOS transistor also has significantly better radiation tolerance for both total ionizing dose effects and single event effects. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Multi-output POL converters such as Alphacore’s solution allows compact, cost-effective spacecrafts, such as nanosatellites, to deliver capabilities that traditionally require larger satellites. It can also be applied to support future heliophysics missions like AWE launching in 2022, PUNCH and TRACERS, both launching in 2023, and IMAP launching in 2024. Future outer planets instruments that may benefit include the Galaxy Evolution Probe, PICO, POEMMA. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): Non-NASA applications for Alphacore’s solution include planned constellations of nanosatellites or CubeSats for hypersonic missile defense and the United States Space Force, commercial spaceflight companies like SpaceX and Blue Origin, and satellite-based weather, data and global intelligence companies like Planet Labs and Capella Space. Duration: 6

In response to NASA SBIR topic S3.08 Command, Data Handling, and Electronics (SBIR), Alphacore Inc. will develop a single-inductor, multiple output (SIMO) high-efficiency point of load (POL) DC-DC converter. We have code-named this exciting technology “POLESTAR” (Point of Load converter with high Efficiency, SIMO architecture and Tolerance Against Radiation). The technology has excellent commercial potential. For typical NASA missions, both mass and power consumption and wide temperature operation is a critical need. Especially for missions requiring mobility, overall SWaP as well as volume is dominated by motor drive and associated electronics. In the Phase II of this project, Alphacore Inc., will design, fabricate and test a buck DC-DC converter that can directly convert voltages from 11V to 36V, down to multiple required power rails ranging from 1.5V to 5V, while supporting at least 10A of current to the load. In the Phase I program, Alphacore Inc. designed a digitally intensive, high-efficiency, radiation hard, hybrid GaN/CMOS integrated single controller, enabling single-inductor multiple output (SIMO) operation. The developed controller enabled a reduced component count, enabling reduced failure modes, lower PCB area. This solution includes all controller circuitry and drivers integrated in a single CMOS ASIC chip, as well as the GaN-based primary DC-DC converter’s power stage in a single module. The hybrid module is planned to have a small form factor, namely 15mm x 15mm x 4mm that can generate 4 supply rails all from a single module. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Alphacore’s high performance DC/DC converters will bridge the gap in spacesuits designed for deep space and surface missions. They will be suitable for smart instruments and controllers used in spacesuit life support systems for NASA’s human missions to Mars and the Deep Space Gateway missions. The proposed solution will also benefit NASA’s robotic systems such as the SPIDER and the Canadaarm3. Our solution can efficiently power up to 3 loads with a single inductor, and enable significant reduction in size and weight for future NASA platforms. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): Our design is an excellent fit for key SWaP, Hi-Rel, and high-radiation applications such as cubesats, nanosats, robotics, autonomous aircrafts/spacecrafts, and constellation satellites to be operated in environments ranging from LEO to deep space and planetary missions. Other applications include defense and aerospace-related power management for controllers and smart devices as well. Duration: 24