PATENT DOCUMENT

Publication Number: US-11375607-B2
Application Number: US-201916551303-A
Country: US
Kind Code: B2

Title: Mirrored voltage regulator for high-current applications and method the same

Abstract:
The disclosed technology relates to a power supply circuit that utilizes a double-sided printed circuit board (PCB) that has a first surface and a second surface. The second surface is disposed opposite the first surface. Mounted on the first surface is a first power stage and a first inductor. Mounted on the second surface is a second power stage and a second inductor. The second power stage is disposed opposite the first power stage. The second inductor is disposed opposite the first inductor.

Claims:
What is claimed is: 
     
       1. A power-supply circuit, comprising:
 a double-sided printed circuit board (PCB) comprising a first surface and a second surface, the second surface disposed opposite the first surface; 
 a first power stage mounted to the first surface of the PCB; 
 a second power stage mounted to the second surface of the PCB and disposed opposite the first power stage; 
 a first inductor mounted to the first surface of the PCB; and 
 a second inductor mounted to the second surface of the PCB and disposed opposite the first inductor, wherein during operation, the first inductor and the second inductor produce electromagnetic noise in opposing phases; 
 wherein each of the first and second inductors are at least partially surrounded by an outer shield that transfers heat away from the PCB, and 
 wherein the shield comprises a bonding surface disposed on a bottom portion of the shield, the bonding surface having an area extends across a width of the first and second inductors, respectively, for mounting to the PCB. 
 
     
     
       2. The power-supply circuit of  claim 1 , further comprising:
 a first capacitor mounted to the first surface of the PCB; and 
 a second capacitor mounted to the second surface of the PCB and disposed opposite the first capacitor. 
 
     
     
       3. The power-supply circuit of  claim 1 , wherein each of the first and second power stages comprise an HS MOSFET, an LS MOSFET, and a driver. 
     
     
       4. The power-supply circuit of  claim 1 , wherein a pin arrangement of the second power stage is mirrored to a pin arrangement of the first power stage. 
     
     
       5. The power-supply circuit of  claim 1 , wherein a conductive pattern disposed on the second surface of the PCB is mirrored to a conductive pattern disposed on the first surface of the PCB. 
     
     
       6. An electronic device, comprising:
 a plurality of multi-phase voltage regulators, each voltage regulator comprising: 
 a double-sided printed circuit board (PCB) comprising a first surface and a second surface, the second surface disposed opposite the first surface; 
 a first power stage mounted to the first surface of the PCB; 
 a second power stage mounted to the second surface of the PCB and disposed opposite the first power stage; 
 a first inductor mounted to the first surface of the PCB; 
 a second inductor mounted to the second surface of the PCB and disposed opposite the first inductor, wherein during operation, the first inductor and the second inductor produce electromagnetic noise in opposing phases; 
 wherein each of the first and second inductors are at least partially surrounded by an outer shield that transfers heat away from the PCB; 
 wherein the shield comprises a bonding surface disposed on a bottom portion of the shield, the bonding surface having an area extends across a width of the first and second inductors, respectively, for mounting to the PCB; and 
 wherein each of the plurality of multi-phase voltage regulators, during operation, provide current at a common target output voltage to a load. 
 
     
     
       7. The electronic device of  claim 6 , wherein each voltage regulator further comprises:
 a first capacitor mounted to the first surface of the PCB; and 
 a second capacitor mounted to the second surface of the PCB and disposed opposite the first capacitor. 
 
     
     
       8. The electronic device of  claim 6 , wherein each of the first and second power stages comprise an HS MOSFET, an LS MOSFET, and a driver. 
     
     
       9. The electronic device of  claim 6 , wherein a pin arrangement of the second power stage is mirrored to a pin arrangement of the first power stage. 
     
     
       10. The electronic device of  claim 6 , wherein a conductive pattern disposed on the second surface of the PCB is mirrored to a conductive pattern disposed on the first surface of the PCB. 
     
     
       11. A method for increasing a power density of a power-supply circuit, the method comprising:
 mounting a first power stage on a first surface of a double-sided printed circuit board (PCB), the first power stage having a first pin arrangement; 
 mounting a second power stage on a second surface of the PCB, the second surface disposed opposite the first surface, the second power stage having a second pin arrangement that is mirrored to the first pin arrangement; 
 mounting a first inductor to the first surface of the PCB; 
 mounting a second inductor to the second surface of the PCB, wherein, during operation, the first inductor and the second inductor produce electromagnetic noise in opposing phases; and 
 at least partially surrounding each of the first and second inductors by an outer shield that transfers heat away from the PCB, and further comprising soldering a bonding surface of the shield to the PCB, wherein the bonding surface has an area that extends across a width of the first and second inductors, respectively. 
 
     
     
       12. The method of  claim 11 , further comprising:
 mounting a first capacitor to the first surface of the PCB; and 
 mounting a second capacitor to the second surface of the PCB. 
 
     
     
       13. The method of  claim 11 , wherein each of the first and second power stages comprise an HS MOSFET, an LS MOSFET, and a driver. 
     
     
       14. The method of  claim 11 , wherein a conductive pattern disposed on the second surface of the PCB is mirrored to a conductive pattern disposed on the first surface of the PCB.

Description:
PRIORITY 
     This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/825,336, entitled “MIRRORED VOLTAGE REGULATOR FOR HIGH-CURRENT APPLICATIONS,” filed on Mar. 28, 2019, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to power supplies, and more particularly, to a high density, multi-phase mirrored voltage regulator for high-current applications. 
     BACKGROUND 
     Voltage regulators are used in a wide variety of circuits in order to provide a regulated output voltage to particular circuits. In high-current applications, voltage regulators may be implemented in a multi-phase architecture and in stages. Each of the stages may contribute to generating the output voltage based on supplied input voltage (e.g. from an external source). The stages may be coupled to one another, with capacitors coupled to the output of each stage. These capacitors may stabilize the voltage that is output by each of the stages. Generally, as certain applications may require higher current, a number of voltage regulators arranged on a printed circuit board or PCB may be increased. An increase in a number of voltage regulators, however, may result in increased acoustic noise, electromagnetic noise, and/or operating temperatures that impact user experience. 
     SUMMARY 
     The disclosed embodiments provide for a power-supply that includes a double-sided printed circuit board comprising a first surface and a second surface disposed opposite the first surface, a first power stage mounted to the first surface of the PCB, a second power stage mounted to the second surface of the PCB opposite the first power stage, a first inductor mounted to the first surface of the PCB, and a second inductor mounted to the second surface of the PCB opposite the first inductor. During operation, the first and second inductors each produce electromagnetic noise in opposing phases resulting in the cancellation of the noise generated by the first and second inductors. 
     The disclosed embodiments provide for an electronic device that uses a plurality of multi-phase voltage regulators for providing power to the electronic device. Each voltage regulator includes a double-sided printed circuit board comprising a first surface and a second surface disposed opposite the first surface, a first power stage mounted to the first surface of the PCB, a second power stage mounted to the second surface of the PCB opposite the first power stage, a first inductor mounted to the first surface of the PCB, and a second inductor mounted to the second surface of the PCB opposite the first inductor. During operation, the first and second inductors each produce electromagnetic noise in opposing phases resulting in the cancellation of the noise generated by the first and second inductors. During operation, each of the plurality of multi-phase voltage regulators provide current at a common target output voltage to a load of the electronic device. 
     In some embodiments, a method for increasing a power density of a power-supply circuit is disclosed. The method includes mounting a first power stage on a first surface of a double-sided printed circuit board. The first power stage has a first pin arrangement. The method also includes mounting a second power stage on a second surface of the PCB opposite the first surface. The second power stage has a second pin arrangement that is mirrored to the first pin arrangement. The method further includes mounting a first inductor to the first surface of the PCB, and mounting a second inductor to the second surface of the PCB. During operation, the first and second inductors each produce electromagnetic noise in opposing phases resulting in the cancellation of the noise generated by the first and second inductors. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments herein may be better understood by referring to the following description in conjunction with the accompanying drawings in which like reference numerals indicate identical or functionally similar elements. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
         FIG. 1  illustrates a perspective view of a voltage regulator, in accordance with various aspects of the subject technology; 
         FIG. 2  illustrates a cross section view of a voltage regulator, in accordance with various aspects of the subject technology; 
         FIG. 3  illustrates a top view of an inductor mounting configuration on a printed circuit board, in accordance with various aspects of the subject technology; 
         FIG. 4  illustrates a block diagram of an electronic device that includes a plurality of multi-phase voltage regulators, in accordance with various aspects of the subject technology; and 
         FIG. 5  illustrates an exemplary method for increasing a power density of a power-supply circuit, in accordance with various aspects of the subject technology. 
         FIG. 6  illustrates a cross section view of an exemplary double-sided PCB. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. 
     A conventional voltage regulator may generate 50-60 amperes (Amps) per phase. In applications requiring 300-400 Amps, voltage regulators may be arranged side-by-side on a printed circuit board or PCB in a 6-8 phase configuration. Arranging voltage regulators side-by-side, however, results in an increased footprint within devices. In applications requiring higher current, such as 600 Amps or more, increasing the number of voltage regulators arranged side-by-side on a surface of a PCB may not be possible due to limited physical space within electronic devices, and may further affect user experience via increases in acoustic noise, electromagnetic noise, and/or operating temperature. 
     The disclosed technology addresses the foregoing limitations of conventional power-supply circuits by mirroring components of a voltage regulator on opposite or both sides of a PCB to increase packaging efficiency while reducing or canceling acoustic noise and/or electromagnetic noise. Specifically, because ceramic capacitors are prone to vibrate due to “Piezo-Electric” effect, when the vibration frequency is in audible range the resulting acoustic-noise may affect user experience. In one aspect, by mirroring ceramics capacitors on opposite or both sides of the PCB, vibration of the capacitors mitigated. In another aspect, because output filter inductors are also known to vibrate due to “Magnetostriction” phenomenon, mirroring output filter inductors on opposite or both sides of the PCB mitigates vibration. In addition, by increasing a contact area between the PCB and an inductor of the voltage regulator, acoustic noise caused by vibration of the inductor may be minimized or eliminated. Further, by partially or entirely surrounding the inductor with a shield and increasing a contact area between the PCB and the inductor, heat transfer from the PCB to the shield is improved to thereby more efficiently remove and manage heat generated by the voltage regulator while reducing electromagnetic interference. 
       FIG. 1  illustrates a perspective view of a voltage regulator  100 , in accordance with various aspects of the subject technology. The voltage regulator  100  may comprise a mirrored and horizontally symmetrical two-phase DC-DC power-supply circuit. Each phase of the two-phase voltage regulator  100  comprises a set of input and output capacitors, a power stage, and an inductor. Referring to  FIG. 1 , the voltage regulator comprises a double-sided PCB  110  with a first surface  112 A and a second surface  112 B that opposes the first surface  112 A. Mounted on the first surface  112 A of the PCB  110 , are a first set of input and output capacitors  120 A, a first power stage  130 A, and a first inductor  140 A. Mounted on the second surface  112 B of the PCB  110 , are a second set of input and output capacitors  120 B, a second power stage  130 B, and a second inductor  140 B. The second set of capacitors  120 B may be electrically coupled to the second surface  112 B of the PCB  110  at a location that is directly opposite of the first set of capacitors  120 A. The second power stage  130 B may be electrically coupled to the second surface  112 B of the PCB  110  at a location that is directly opposite of the first power stage  130 A. The second inductor  140 B may be electrically coupled to the second surface  112 B of the PCB  110  at a location that is directly opposite of the first inductor  140 A. 
     A first phase of the two-phase voltage regulator  100  may comprise the first set of capacitors  120 A, the first power stage  130 A, and the first inductor  140 A. A second phase of the two-phase voltage regulator  100  may comprise the second set of capacitors  120 B, the second power stage  130 B, and the second inductor  140 B. In some aspects, the components (e.g., the first set of capacitors  120 A, the first power stage  130 A, the first inductor  140 A, the second set of capacitors  120 B, the second power stage  130 B, and the second inductor  140 B) of the voltage regulator  100  are arranged on the first surface  112 A and the second surface  112 B in a mirrored configuration such that the voltage regulator  100  is symmetrical about a horizontal plane  111  (as shown in  FIG. 2 ). 
       FIG. 6  illustrates a cross section view of an exemplary double-sided PCB. A conductive pattern  601   b  disposed on the second surface  112 B of the PCB  110  may be mirrored to a conductive pattern  601   a  disposed on the first surface  112 A of the PCB  110 . In some aspects, because the conductive pattern  601   b  of the second surface  112 B of the PCB  110  is mirrored to the conductive pattern  601   a  disposed on the first surface  112 A of the PCB  110 , any electromagnetic noise generated by the voltage regulator  100  is canceled because the first surface  112 A and the second surface  112 B are each carrying the same amount of current, but in opposite directions, thereby resulting in their respective moments cancelling each other 
       FIG. 2  illustrates a cross section view of the voltage regulator  100 , in accordance with various aspects of the subject technology. As shown, the second set of capacitors  120 B are mounted to the second surface  112 B of the PCB  110  and may be disposed opposite of the first set of capacitors  120 A that are mounted on the first surface  112 A of the PCB  110 . The second power stage  130 B is mounted to the second surface  112 B of the PCB  110  and may be disposed opposite of the first power stage  130 A that is mounted on the first surface  112 A of the PCB  110 . The second inductor  140 B is mounted to the second surface  112 B of the PCB  110  and may be disposed opposite of the first inductor  140 A that is mounted on the first surface  112 A of the PCB  110 . 
     In some aspects, because the second inductor  140 B is mounted directly opposite of the first inductor  140 A, any electromagnetic noise generated by the first and second inductors,  140 A and  140 B respectively, is canceled because during operation, the first inductor  140 A and the second inductor  140 B produce electromagnetic noise in opposing phases. In another aspect, because the second inductor  140 B is mounted directly opposite of the first inductor  140 A, vibration or acoustic noise generated by the first and second inductors,  140 A and  140 B respectively, is canceled because during operation, the first inductor  140 A and the second inductor  140 B vibrate in opposing phases. 
     Each of the first and second power stages,  130 A and  130 B respectively, may comprise an integrated circuit (“IC”), such as a switch (e.g., MOSFET), a driver, and any other semiconductors. In some examples, the first and second power stages,  130 A and  130 B respectively, may comprise a high-side MOSFET and/or a low-side MOSFET to facilitate a power conversion in voltage regulator  100 . In one aspect a pin arrangement of the second power stage  130 B is mirrored to a pin arrangement of the first power stage  130 A. For example, referring to  FIG. 2 , the first power stage  130 A may comprise a first pin  132 A with a first functionality disposed a first distance d 1  from a side of the first power stage  130 A, a second pin  133 A with a second functionality disposed a second distance d 2  from the side of the first power stage  130 A, and one or more pins  134 N with one or more functionalities. The second power stage  130 B may comprise a first pin  132 B having the same first functionality as the first pin  132 A of the first power stage  130 A, a second pin  133 B having the same second functionality as the second pin  133 A of the first power stage  130 A, and one or more pins  135 N with one or more functionalities that are the same as the one or more functionalities as the pins  134 N of the first power stage  130 A. In one aspect, because the second power stage  130 B is disposed opposite of the first power stage  130 A, the first pin  132 B of the second power stage  130 B is disposed directly opposite of the first pin  132 A of the first power stage  130 A at the first distance d 1  from the side of the first power stage  130 A. In another aspect, because the second power stage  130 B is disposed opposite of the first power stage  130 A, the second pin  133 B of the second power stage  130 B is disposed directly opposite of the second pin  133 A of the first power stage  130 A at the second distance d 2  from the side of the first power stage  130 A. In yet another aspect, because the second power stage  130 B is disposed opposite of the first power stage  130 A, the one or more pins  135 N of the second power stage  130 B are disposed directly opposite of the one or more pins  134 N of the first power stage  130 A. 
     The first and second inductors,  140 A and  140 B respectively, may each comprise an outer shield  142  that partially or completely surrounds the first and second inductors,  140 A and  140 B respectively. The shield  142  may be formed of a heat conducting material, such as a metal alloy, and is configured to transfer heat away from the PCB  110 . In one aspect, the shield  142  may further comprise a plurality of fins to increase dissipation of heat transferred from the PCB to the shield. In some aspects, a thermal conducting and electrically insulating insulator  143  may be disposed between the shield  142  and the first and second inductors,  140 A and  140 B respectively. 
       FIG. 3  illustrates a top view of an inductor mounting configuration disposed on the PCB  110 , in accordance with various aspects of the subject technology. An area for mounting the first inductor  140 A is provided on the first surface  112 A of the PCB  110  and an area for mounting the second inductor  140 B is provided on the second surface  112 B of the PCB  110 . The area on the first and second surfaces,  112 A and  112 B respectively, may each comprise a first pad  144 , a second pad  145 , and a third pad  146 . The first pad  144  and the second pad  145  are each configured to electrically connect to terminals of the first and second inductors,  140 A and  140 B respectively. The third pad  146  is configured to be soldered to a corresponding bonding surface disposed on a bottom portion of the shield  142  to increase a surface area of the shield  142  that is in direct contact with the PCB  110  to thereby dampen vibration and reduce acoustic noise, as well as improve heat transfer between the PCB and the shield  142 . 
     In one aspect, the third pad  146  and the bonding surface of the shield  142  may each have an area that exceeds the area of the first pad  144  and the second pad  145 . In another aspect, the third pad  146  and the bonding surface of the shield  142  may each have an area that occupies physical space between the first pad  144  and the second pad  145 . In yet another aspect, the third pad  146  and the bonding surface of the shield  142  may each have an area that extends across a first width w 1  of the first and second inductors,  140 A and  140 B respectively. In yet another aspect, the third pad  146  and the bonding surface of the shield  142  may each have an area that extends across a second width w 2  of the first and second inductors,  140 A and  140 B respectively. 
       FIG. 4  illustrates a block diagram of an electronic device  200  that includes a plurality of multi-phase voltage regulators  100 , in accordance with various aspects of the subject technology. The electronic device  200  includes at least one instance of an integrated circuit  220  coupled to external memory  230 . The integrated circuit  220  may include a memory controller that is coupled to the external memory  230 . The integrated circuit  220  is coupled to one or more peripherals  240  and the external memory  230 . A power supply  210  is also provided which supplies the supply voltages to the integrated circuit  220  as well as one or more supply voltages to the memory  230  and/or the peripherals  240 . In some embodiments, more than one instance of the integrated circuit  220  may be included (and more than one external memory  230  may be included as well). 
     The power supply  210  comprises a plurality of DC-DC two-phase voltage regulators  100  (as described above) that are arranged within the electronic device  200  to support the power demands of the electronic device  200 , components, and/or peripherals  240 . For example, if each phase of the voltage regulator  100  is configured to support 50-60 Amps, each voltage regulator  100  may support 100-110 Amps. Based on the power requirements of the electronic device  200 , a number of voltage regulators  100  utilized by the electronic device  200  may be increased to satisfy the power requirements of the electronic device. Specifically, should the electronic device  200  require more than 600 Amps peak current for a graphics processing unit (GPU) or a central processing unit (CPU), eight voltage regulators  100  (16 phases) may be arranged within the electronic device to provide 800-880 Amps. In some aspects, by mirroring the components on each voltage regulator  100  and arranging the components so that they are horizontally symmetrical, as described above, the power supply  210  is capable of providing high-current within a smaller footprint over conventional power supplies (which arrange components side-by-side), while reducing or eliminating electromagnetic noise and/or acoustic noise through cancelation (as described above), and improving thermal performance. In another aspect, each of the plurality of multi-phase voltage regulators  100 , during operation, provide current at a common target output voltage to a load. 
     The peripherals  240  may include any desired circuitry, depending on the type of electronic device  200 . For example, in one embodiment, the electronic device  200  may be a mobile device (e.g. personal digital assistant (PDA), tablet, laptop, smart phone, etc.) and the peripherals  240  may include devices for various types of wireless communication, such as WiFi, Bluetooth, cellular, global positioning system, etc. The peripherals  240  may also include additional storage, including RAM storage, solid-state storage, or disk storage. The peripherals  240  may include user interface devices such as a display screen, including touch display screens or multitouch display screens, keyboard or other input devices, microphones, speakers, etc. In other embodiments, the electronic device  200  may be any type of computing system (e.g. desktop personal computer, workstation, watch, wearable device, and/or other type of computing system). 
     The external memory  230  may include any type of memory. For example, the external memory  230  may be SRAM, dynamic RAM (DRAM) such as synchronous DRAM (SDRAM), double data rate (DDR, DDR2, DDR3, LPDDR1, LPDDR2, etc.) SDRAM, RAMBUS DRAM, etc. The external memory  230  may include one or more memory modules to which the memory devices are mounted, such as single inline memory modules (SIMMs), dual inline memory modules (DIMMs), etc. 
       FIG. 5  illustrates an exemplary method  300  for increasing a power density of a power-supply circuit, in accordance with various aspects of the subject technology. It should be understood that, for any process discussed herein, there can be additional, fewer, or alternative steps performed in similar or alternative orders, or in parallel, within the scope of the various embodiments unless otherwise stated. 
     At operation  310 , a first power stage is mounted on a first surface of a double-sided PCB. The first power stage has a first pin arrangement. At operation  320 , a second power stage is mounted on a second surface of the PCB. The second surface of the PCB is disposed opposite the first surface. The second power stage has a second pin arrangement that is mirrored to the first pin arrangement. Each of the first and second power stages may comprise IC having an HS MOSFET, an LS MOSFET, and a driver. At operation  330 , a first inductor is mounted to the first surface of the PCB. At operation  340 , a second inductor is mounted to the second surface of the PCB. A first set of capacitors may be mounted to the first surface of the PCB and a second set of capacitors may be mounted to the second surface of the PCB. 
     An outer shield may surround each of the first and second inductors to transfer heat away from the PCB. A bonding surface disposed on a bottom portion of the shield may be soldered to the PCB. The bonding surface may have an enlarged area, compared to other terminals extending from the inductors, to improve heat transfer between the PCB and the inductor, and to further dampen acoustic noise or vibration generated by each inductor. By increasing an area that is soldered and mechanically coupled to the PCB, the inductor is physically stabilized such that any vibration or acoustic noise generated by the inductor is more efficiently transferred to the PCB for dampening. The bonding surface, as described above, may have an area that extends across a width of the inductor. During operation, the first inductor and the second inductor produce electromagnetic noise in opposing phases to thereby cancel any electromagnetic noise generated by each respective inductor. 
     In some aspects, the power supply circuit comprises a two phase voltage regulator. A first phase of the two-phase voltage regulator may comprise the first set of capacitors, the first power stage, and the first inductor. A second phase of the two-phase voltage regulator may comprise the second set of capacitors, the second power stage, and the second inductor. By arranging the components of the voltage regulator so that each component is mirrored on a top and bottom surface of the PCB, electromagnetic noise generated in the first phase, is effectively canceled by electromagnetic noise generated in the second phase. Specifically, because each phase carries the same current, but in opposing directions, the electromagnetic moments generated by the first phase and second phase cancel each other out. In another aspect, acoustic noise generated by the inductors is canceled because the inductors are mounted in a mirrored configuration that is symmetrical about a horizontal plane. Specifically, because the first inductor and the second inductor operate in opposing phases, acoustic noise or vibration is canceled. 
     Although a variety of examples and other information was used to explain aspects within the scope of the appended claims, no limitation of the claims should be implied based on particular features or arrangements in such examples, as one of ordinary skill would be able to use these examples to derive a wide variety of implementations. Further and although some subject matter may have been described in language specific to examples of structural features and/or method steps, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to these described features or acts. For example, such functionality can be distributed differently or performed in components other than those identified herein. Rather, the described features and steps are disclosed as examples of components of systems and methods within the scope of the appended claims.

Metadata:
Filing Date: 20190826
Publication Date: 20220628
Grant Date: 20220628
Priority Date: 20190328
Inventors: ZHANG, KEJIU
AKRE, SUNIL M.
Assignee: APPLE INC
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Family ID: 72605069