Integrated circuit having insulation breakdown detection

Methods and apparatus for an integrated circuit having first and second domains with an insulative material electrically isolating the first and second domains. A conductive shield is disposed between the first and second domains and a current sensor has at least one magnetoresistive element proximate the shield to detect current flow in the shield due to breakdown of the insulative material.

BACKGROUND

As is known in the art, integrated circuits can include an insulative material to electrically isolate one domain from another. The domains can be at different voltage potentials. As the insulative material breaks down, the electrical isolation of the regions can be degraded, which can impair operation of the insulative material. In some cases, breakdown of the insulative material may create dangerous conditions.

SUMMARY

The present invention provides method and apparatus for an integrated circuit to detect breakdown of an insulation system on the integrated circuit used for signal isolation. It is understood that embodiments of the invention are directed to insulation breakdown that is a relatively ‘instantaneous’ event as opposed to relatively slow degradation over time.

In embodiments, the isolated integrated circuit can be disconnected to protect a lower of high and low voltage domains, for example. In embodiments, a signal isolator integrated circuit package includes high and low voltage domains isolated by a layer of insulative material with a detection module to detect breakdown of the insulative material. In some embodiments, current flow corresponding to insulation breakdown is latched to hold the state while disconnection of the higher voltage domain can occur, for example.

In an embodiment, a signal isolator integrated circuit includes high and low voltage domains with conductive structures for data transmission on each side; which could include in one of each of the voltage domains a coil and current sensor, two coils for magnetic coupling or capacitor plates for capacitive coupling; separated by an insulative material and an insulation breakdown detection module. It is understood that any of the conductive structures could be used for data transmission; for the purposes of illustration the coil and current sensor will be used as the preferred method of data transmission. In embodiments, the integrated circuit can be used for isolating digital or analog signals, with one or more integrated circuit chips in a single package. In embodiments, the insulating layer comprises a polymer, ceramic, oxide or other suitable material. The voltage between the domains can depend on the application in which the signal isolator is used. As the isolation material breaks down, electrical isolation between the circuits of the high and low voltage domains is compromised. The higher voltage can create current flow with the potential to harm circuitry on the lower voltage domain.

In embodiments, a current detection module of the integrated circuit can detect current flow from the high voltage side to the low voltage side as insulation breaks down. In some embodiments, an integrated circuit can include an electric shield comprising a conductive material between the isolated circuits. The shield shunts current to a node, such as ground. The current detection module can include a current sensor proximate the shield carrying the breakdown current to detect the flow of current.

In embodiments, the current sensor comprises a magnetoresistive material which changes impedance due to the flow of the breakdown current. This change in impedance can be used to detect breakdown current flow and to disconnect the isolated circuits from each other. For example, a relay or other suitable device can be used for circuit disconnection. In embodiments, the current sensor includes a magnetoresistive element to provide a bi-stable current sensor. The detected current signal latches the breakdown current flow sustaining the detection of the breakdown current flow. To detect a breakdown current flow of either polarity, first and second magnetoresistive devices can be positioned adjacent to the current flow in inverse orientations to the current flow and electrically in parallel. If either one of the inverse magnetoresistive devices detects current flow, the total resistance across the magnetoresistive element will change

In one aspect of the invention, an integrated circuit, comprising: a first domain; a second domain; an insulative material electrically isolating the first and second domains; a conductive shield between the first and second domains; a current sensor having at least one magnetoresistive element proximate the shield to detect current flow in the shield due to breakdown of the insulative material.

An integrated circuit can further include one or more of the following features: the integrated circuit comprises a signal isolator, the magnetoresistive element comprises a bi-stable latch, at least one switch to selectively connect and disconnect the first and second domains, at least one magnetoresistive element includes a first magnetoresistive element to detect the current flow in a first direction and a second magnetoresistive element to detect the current flow in a second direction, which is opposite to the first direction, a first breakdown condition corresponds to the current flow in the first direction above a first threshold, a second breakdown condition corresponds to the current flow in the second direction above a second threshold, the first domain comprises a first conductive structure and the second domain comprises a second conductive structure, and wherein the shield is disposed between the first and second conductive structure, and/or the shield is offset a given lateral distance from a vertical alignment of the first and second conductive structure. The conductive structure is part of a data transmission mechanism, and can be first and second coils magnetically coupled or first and second capacitive plates.

In another aspect, a method comprises: employing a first domain and a second domain; employing an insulative material electrically isolating the first and second domains; employing a conductive shield between the first and second domains; and employing a current sensor having at least one magnetoresistive element proximate the shield to detect current flow in the shield due to breakdown of the insulative material.

A method can further include one or more of the following features: the integrated circuit comprises a signal isolator, the magnetoresistive element comprises a bi-stable latch, at least one switch to selectively connect and disconnect the first and second domains, the at least one magnetoresistive element includes a first magnetoresistive element to detect the current flow in a first direction and a second magnetoresistive element to detect the current flow in a second direction, which is opposite to the first direction, a first breakdown condition corresponds to the current flow in the first direction above a first threshold, a second breakdown condition corresponds to the current flow in the second direction above a second threshold, the first domain comprises a first coil and the second domain comprises a second coil magnetically coupled to the first coil, and wherein the shield is disposed between the first and second coils, and/or the shield is offset a given lateral distance from a vertical alignment of the first and second coils.

In a further aspect, a device comprises: a first domain; a second domain; an insulator means for electrically isolating the first and second domains; a conductive shield means between the first and second domains; a current sensor means having at least one magnetoresistive element proximate the shield means for detecting current flow in the shield due to breakdown of the insulator means.

DETAILED DESCRIPTION

FIG. 1shows an example system100having first and second domains102,104electrically isolated by an insulative material106, which can be provided in a layer. The system100further includes a breakdown detection module108to detect breakdown of the insulative material106which can reside in one of the domains. In embodiments, a current can flow between the first and second domains102,104due to breakdown of the insulative material106. The breakdown detection module108can include a current sensor to detect the current flow between the first and second domains102,104.

It is understood that the term “domain” should be construed broadly to include any circuitry associated with a particular circuit supply voltage, at a particular voltage level that is completely separated from another circuit with a different power supply voltage, generally at a different voltage level. The separation can be for safety or functional purposes. In embodiments, the first domain102includes circuitry configured, at least in part, for operation at a first voltage level and the second domain104includes circuitry configured, at least in part, for operation at a second voltage level. The first and second voltage levels can be different voltage levels. In embodiments, the first and second domains102,104can be provided on different die, or the same die. An example voltage range of operation is from about 5V in one domain to about 60V to many kilovolts for safety isolation. For functional isolation, both domains would generally have a voltage differential of <60V.

FIG. 2shows an example signal isolator200having insulative material breakdown material in accordance with example embodiments of the invention. The signal isolator200includes first and second die202,204that form part of an integrated circuit package206. In an embodiment, the IC package206includes a first input signal INA connected to the first die202and a first output signal OUTA connected to the second die204. The IC package206further includes a second input signal INB connected to the second die204and a second output signal OUTB to the first die204. The first and second die202,204are separated by a barrier region208, such as an isolation barrier formed of an insulative material. The IC package206includes an isolation breakdown module209to detect current flow between the first and second die202,204due to breakdown of the isolation barrier208, as described more fully below.

It is understood that signal isolator includes any device that provides signal isolation for analog, digital, sensing element isolators, and the like.

In embodiments, the first die202includes a first transmit module210and the second die includes a first receive module212that provides a signal path from the first input signal INA to the first output signal OUTA across the barrier208. The second die204includes a second transmit module214and the first die204includes a second receive module216that provides a signal path from the second input signal INB to the second output signal OUTB across the barrier208.

It is understood that any practical number of transmit, receive, and transmit/receive modules can be formed on the first and/or second die to meet the needs of a particular application. It is further understood that transmit, receive, and transmit/receive modules can comprise the same or different components. In addition, in embodiments, bi-directional communication is provided across the barrier. Further, circuitry in the first and/or second die can be provided to process signals, perform routing of signals, and the like. In some embodiments, sensing elements are formed in, on, or about the first and/or second die.

FIG. 2shows an example signal isolator200having magnetic signal latching of signals from a transmitter202to a receiver204separated by an isolation barrier206. In embodiments, the transmitter202is disposed on a first die208and the receiver204is disposed on a second die210, where the first and second die have different voltage domains.

FIGS. 3A and 3Bshow an example signal isolator300having a magnetoresistive (MR) sensor302proximate a conductive shield304for detecting current flow due to breakdown of a dielectric layer306between a transmit coil308and a receive coil310. In embodiments, the transmit coil308can be provided as the transmitter210ofFIG. 2and the receive coil310can be provided as the receiver212ofFIG. 2.

As the insulating capability of the dielectric layer306breaks down, a current can flow, for example, in the conductive shield304, as indicated by arrow312(FIG. 3B). As shown inFIG. 3B, the current flow312generates a magnetic field314. In embodiments, the magnetoresistive sensor302detects the magnetic field314from the current flow312for detecting the insulation306breakdown. In embodiments, the magnetoresistive sensor302is located a given distance from an overlap of the transmit and receive coils308,310. In the illustrated embodiment, the magnetoresistive sensor302is a distance to the right of the vertical alignment of the transmit and receive coils308,310. In embodiments, the magnetoresistive sensor302comprises a bi-stable magnetoresistive element.

It is understood that the transmit and receive coils can have any suitable configuration in the number of coils, thickness, geometry, etc., to meet the needs of a particular application. It is further understood that example insulative materials comprise Polyimide, BCB, silicon oxide (including but not limited to SIO2), silicon nitride, and any combinations thereof.

FIG. 4Ashows an example magnetoresistive sensor400of a signal isolator having a bridge configuration402. MR elements404aand404cwill saturate in one direction and MR elements404band404dwill saturate in the opposite direction. These saturation levels will be latched, i.e. remain in state, until an opposite magnetic field of large enough amplitude overcomes the coercive force of the MR element, as shown inFIG. 4B, changing the state of the MR magnetic latch. In the illustrative embodiments, these opposite states of the magnetorestive sensing elements404a-dare coupled to an amplifier or comparator406to generate an output voltage equal to the latched state of the MR elements.FIG. 4Bshows an example bi-stable latch that holds a first state until transitioned to a second state.

FIG. 5shows an example circuit500having insulation breakdown detection in accordance with example embodiments of the invention. The circuit500includes active circuitry502, e.g., the signal isolator circuitry, coupled to a supply voltage Vs via a first switch504and ground506via a second switch508. The active circuitry502also includes an I/O signal510coupled to a SELV (safety extra-low voltage) circuit via a third switch512. In embodiments, the breakdown detection circuitry is passive. In general, the active circuitry will be damaged by insulation breakdown.

The circuit500includes a conductive shield514coupled to ground506. A first magnetic field sensor516having a first orientation is proximate the shield514at a first position and a second magnetic field sensor518having a second orientation is proximate the shield at a second position. The first magnetic field sensor516detects current flow in the shield514in a first direction and the second magnetic field sensor518detects current flow in the shield in the opposite direction. Based upon whether the current flow is above a given threshold, for example the switches504,508,512can be controlled to open. For example, if the current flow is above a first threshold in the first direction, the first magnetic field sensor516can change state. Based on the change of state, the switches can be opened to prevent damage to the SELV circuit, for example, due to breakdown of insulative material. Similarly, current flow above a second threshold in the opposite direction can be detected by the second magnetic field sensor518.

As the magnetoresistive elements change in impedance due to current flow in the shield, the circuit connections can be disconnected so that the isolated circuits are not damaged. Switches, relays, and the like can be used to selectively connect and disconnect the isolated circuits. In embodiments, magnetoresistive elements can provide a bi-stable current sensor for latching a detected current signal corresponding to insulation breakdown current flow.

Embodiments of the invention provide detection of breakdown of an insulative material of an integrated circuit. The integrated circuit can be provided, for example, as a signal isolator for isolating digital and/or analog signals or sensors. One or more integrated circuit chips can be provided in a single package. The voltage differential between first and second domains can be relatively high depending on the application so as to result in breakdown of the dielectric material and decreased electrical isolation. As isolation capability breaks down, current can flow between the circuits at different voltage levels potentially damaging circuitry or creating hazardous conditions. Current flow can advantageously be detected using at least one conductive shield and at least one current sensor in an integrated circuit package.

It is understood that the magnetic field sensing elements can comprise any suitable magnetoresistive technologies, including AMR, GMR, TMR, or other magnetoresistive technology. By using a magnetoresistive latch to hold current breakdown data, data can be preserved during external events that disrupt the electrical operation of the active circuitry. Example transmissions can be provided as pulsed current, direct current, continuous frequency (e.g., On-off-Keying or OOK) or other suitable data transmission method.

While example embodiments are shown having a transmitter and receiver on separate die, in other embodiments, they are on the same die. In addition, each die can have any combination of drivers and receivers and each driver and receiver data transmission channel can share features for each individual data channel. In embodiments, outputs can be in buffered with a push-pull, open drain or other such output driver, or the output can be a magnetoresistive device with change in resistance indicating logic states.