ST AN1499 Application note

AN1499
APPLICATION NOTE
DESIGNING A LOW COST POWER BOARD FOR THE
ST92141 MOTOR CONTROL MCU WITHOUT USING IPMs
By Motor Control Competence Center
INTRODUCTION
Power Modules ha ve been i n use for t wenty year s in industr ial m otor drive a pplicati ons. F or power stage designs, they give the advantages of compactness and good thermal behavior.
Over the last few years a new family of Power Modules, called Intelligent Power Modules (IPM), have tried to take the integration of motor drive power stages a step further.
These IPMs target lower power and lower cost motor drive system s compared to those tar­geted by standard Power Modules.
However it is an open question whether these IPMs suit high volume and very co st-sensitive applications, such as the household appliance market.
Figure 1. General System View
AN1499/0202 1/21
1
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 INTELLIGENT POWER MODUL ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 ADVANTAGES OF IPMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Assembly cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Co mpo nent coun t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Reduction i n time to market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.4 Higher reliabi lity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.5 Product compactness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.6 Package ind uc tance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 DRAWBACKS OF IPMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Lead fram e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 He atsink planarity and stiffness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.3 Embedded gate drive & filter cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.4 Ext ernal bootstrap diodes and temperature pro tection neede d . . . . . . . . . . . . . . . . . 5
1.2.5 Co mpo nent choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 AN ALTERNATIVE SOLUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 ADVANTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.1 Assem bly & m ounting cons iderations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.2 Reduction i n time to market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.3 Reliability considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.4 Therm al management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.5 Gate drive optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 DRAWBACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.1 Co mpo nent coun t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.2 PCB connec tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 CONCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 MECHANICAL DATA: ST92141-PLATFO RM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 CONTROL BOARD LAYOUT (ORCAD FILES AVAILABLE) . . . . . . . . . . . . . . . . . . 20
2/21
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21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
1 INTELLIGENT POWER MODULES
These products integrate in a single transfer molded package, six IGBTs, six free wheeling di­odes and the interfacing circuits needed to enable direct control from a microcontroller.
In their low cost version they do not include the front-end rectification diodes, nor do they have a switch or diode for active power factor correction.
External circuits are still needed, such as bootstrap supplies, current sensing and filtering, and auxiliary supply decoupling.
This applic ation n ote a naly zes the a dvant age s an d d raw back s o f this p ower in tegr ation ap ­proach with regard to the constraints of cost sensitive motor drives.
An alternative solution is proposed that fits better to appliance and large volume applications in term of optimization and cost.
1.1 ADVANTAGES OF IPMS
Out of all the advantages that are claimed, the major ones seem to be the following:
– Less assembly cost – Lower component count – Reduction in time to market – Higher reliability – Product compactness – Low inductance package
These are general claims that need to be confronted with reality.
1.1.1 Assembly cost
Assembling an IPM requires placing it on the PCB, wave soldering and later on fixing the heat­sink with s crew s. Th ese o perat ions ar e inde ed less exp ensive th an ass embli ng six d iscre te components. You should note how ever that if an active power fac tor corrector is needed, ex­ternal discrete power components are required.
1.1.2 Component count
This is a clear advantage because nine components are replaced by each IPM. However the need for microcontroller and passive component assembly remains and IPMs do not r em o ve any major manufacturing step.
1.1.3 Reduction in time to market
Layout of IGBT and MO SFET gate drives requires special expertise. U sing an IPM does not require all this expertise, but a good understanding of EMI and parasitic inductance effects is still strongly recommended!
3/21
2
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
Assuming this expertise is available, the estimated saving will be hardly be more than the time it takes to have a coffee break!
1.1.4 Higher reliability
From a silicon point of view , there are still about 1 5 dice inside the modu le with th eir own MTBFs rela ted to j unction te mpe rature as well as m ore than 40 wire bo nds. So th e syst em MTBF may increase because the connection and assembly count decreases. However it may decrease if the heatsink is not perfectly flat below the whole IPM surface.
1.1.5 Product compactness
When just com paring power switches, IP Ms br ing c omp actnes s. But when ta lking ab out the whole system, the difference i s negligible. Passive c omponents , heatsink, PCB and c onnec­tors are by far the most bulky parts.
1.1.6 Package inductance
The only circuit area where IPMs reduce the parasitic inductance is located between the gate drivers and the pow er sw itches. T his is true for the h igh side g ate dri vers but not f or the low side drivers.
Figure 2 shows that during turn-on, the low side gate drive current loop (B) is not internal to the
module but goes outside. In this case, IPMs do not have a significant advantage over discrete solutions.
Figure 2. Low side gate drive current loop
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4/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
1.2 DRAWBACKS OF IPMS
Counterbalancing the advant ages listed above , IPMs have m ajor draw backs that m ake their use in cost sensitive applications rather questionable.
Let’s review these drawbacks:
1.2.1 Lead frame
Due to manufacturing constraints, an IPM has leads on both sides of the pac kage. This means that the PCB must be installed parallel to the pack age. So the heatsink must have its contact base parallel to th e IPM and th e PCB. Whe n you are lo oking for a v ery cheap so lution, this makes the choice of heatsink difficult.
1.2.2 Heatsink planarity and stiffness
Inside the IPM, power switches are soldered directly on a long and thin lead frame. Then this lead frame is fully molded for isolation between the heatsink and the active parts. As a result, these IPMs have a low stiffness and need to be assembled on a good quality heatsink to avoid internal cracks. As a consequence, cheap heatsinks made of metal sheet are not recom­mended. This may lead to additional cost.
1.2.3 Embedded gate drive & filter cost
One sensitive parameter, in terms of optimizing the motor drive cost, is gate drive impedance. By adjusting this imped anc e properly, you can find th e ri ght c ompr omis e b etwee n f ilter cos t and heatsink cost. As IPMs do not give access to the gate drive impedance, you cannot adjust the dV/dt commutation which may lead to additional filter cost.
1.2.4 External bootstrap diodes and temperature protection needed
Most IPMs available today do not hav e over-temperature protec tion. This requires additional external circuits.
As bootstrap diodes are not integrated in the module, they need to be added externally. This leads to additional cost.
1.2.5 Component choice
Needless to say the choice of IPMs today is very scarce and does not match the broad range of power switch and interface circuits. This is a real drawback when cost is all-important.
5/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
2 AN ALTERNATIVE SOLUTION
The basic idea behind the IPM solution consists of reducing the component count, simplifying assembly and making board layout easier. However it has been shown that the cost benefit is not always easy to determine when you calculate at system level.
Another way to split the system consists of grouping all the system SMD components on a small size FR4 board, called the Control Board, and keeping all the power sw itches and dis­crete components on a mother board called the Power Board.
Figure 5, Figure 6 & Figure 7 show an AC motor drive application using this partitioning. An ex -
ample layout and parts list are given in Appendix 2. It is worthwhile to review the advantages and drawbacks of this new partitioning.
2.1 ADVANTAGES
2.1.1 Assembly & mounting considerations
Figure 6 shows a contr ol bo ard s chem atic im plem enting a m icrocon troller, i ts pe ripheral c ir-
cuits and three High Voltage Integrated Circuits for interfacing directly to the Power Board schem atic show n in Figure 7. This microcontroller is dedicated to AC motor control and is housed in a shrink SO34 package (refer to the parts list in Appendix 2 and ST92141 and L6386 datasheet on http:\\www.st.com).
The size of this type of control board is about 26mm by 87mm. This makes use of available FR4 hardware . This board can be plugged into the Power Boar d next t o the discrete power switches. T he Power Board layout is very easy and simple, even if low cost materials like CEM1 are used. This makes the size of the Power Board smaller even if single side copper is used.
The total volume of the Control Board and the power switches is very compact. Moreover, the discrete Power switches can fit many different heatsink configurations, parallel
or perpendicular, with no planarity and stiffness constraints. Another ad vantag e co mes f rom the s olderi ng proces s d ifferen ti ation: SM D com pon ents are
soldered using a reflow process, discrete components go through solder waves. This im­proves the production yield.
Finally, if an active power factor is needed, it is easy to add another switch to the power stage.
2.1.2 Reduction in time to market
The physical spli t between co ntrol circuits and power parts make the system easy to layo ut and quick to debug. T he system power r ange or the input front end can be adapted w ithout af­fecting the Control Board and v ice versa. Any change of microcontroll er package or i ts periph­eral circuits does not interfere with the power stage.
6/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
In other words, the same Control Board can fit different Power Boards. This makes the first design shorter and the future re-design even faster.
2.1.3 Reliability considerations
The reflo w proces s u s ed to sold er the Co nt rol B oa rd is prov en to be m ore rel iable t han the wave process.
The connection between both boards is done during the wave process. Figure 5 shows a typ­ical implementation and Appendix 1 gi ves the results of the v ibration test performed on this as­sembly.
2.1.4 Thermal management
Assembling the d iscr ete comp onen ts b y c lips e nab les the d issip ation to b e spre ad ov er t he whole heatsink surface. This avoids concentrating the losses on a small ar ea and allows you to use cheap heatsink technology made of metal sheet.
2.1.5 Gate drive optimization
Figure 8 shows the influence of the gate drive impedance on the conducted noise. As the
whole gate drive is available on the Control Board, it is easy to adapt the noise level according to the filter attenuation at any time. This noise level optimization can save time and cost.
Moreover the Control Board design allows t he use of ad vanced High Voltage Integrated Cir­cuits that integrate a bootstrap diode and comparators (refer to L6386 on http:\\www.st.com).
The is true for power switch selection (see the fully insulated TO220 products like STGP7NB60HDFP on http:\\www.st.com).
2.2 DRAWBACKS
The main drawbacks relate to:
2.2.1 Component count
Compared to the IPM solution, both the Control Board and the Power Board each implement about six components more.
2.2.2 PCB connections
The double sided Control Board soldering totals 68 contacts that are processed during wave soldering.
7/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
3 CONCLUS ION
This comparison between two different system partitioning methods has shown that the Intel­ligent Module approach is not the most flexible and cheap solution when designing c ost sen­sitive motor control applications.
The alternative solution that is presented gives several advantages that are decisive when cost is the overriding factor:
– Access to low cost heatsink technology and better thermal management – Use of different processes for SMD and through-hole components to improve the production
yield – Fexibility to adapt the Power Board with no impact on the Control Board and vice versa – Access to gate drive impedance to optimize the EMI level at any time – Choice of a large portfolio of interface ICs and power switches
For further details about the Control Board hardware and software features, refer to AN1498.
Figure 3. Control Board high voltage in ter facing side
8/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
Figure 4. Control Board microcontroller side
Figure 5. Control Board plugged into the Power Board next to the discrete parts
9/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
Figure 6. Typical Control Board circuit for AC motor control applications
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DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
Figure 7. Typical Power Board circuit fo r A C m otor control applications
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R77
4.7K
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IC9
SFH617A
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9
R78
4.7K
SFH617A
IC10
J10
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of
Rev
11/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
Figure 8. Conducted noise depending on gate drive impedance
On the left: Rg = 220R on the right: Rg = 82R
12/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
APPENDIX 1: Vibration test results of Control Board and Power Board assembly
VIBRATIONS, SINUSOIDAL
(Stantard: IEC 68-2-6, test Fc)
Electrical limits were tested on two modules after a Vibrations, sinusoidal as below
specified:
Puma Sine Test Synopsis
Test Results:
Reason For Shutdown: Normal Test Completion
Elasped Test Time: 0002:052:054
Elasped Sweeps: 20.00 Remaining Sweeps: 0.00
Points Per Sweep: 800
Test Range: 5.00(Hz) to 2000.00(Hz)
Control Parameters
Control Strategy: Average
Filter Type: Proportional
Filter Specification: 80.00%
Sweep Mode: LOG
Sweep Rate: 1.00 (Oct/Min)
Shaker Limits
Acceleration: 45.0000
Velocity: 59.0551
Displacement: 0.9843
Velocity: 12.0000
Symetric Limits: Yes
Resonance Search And Dwell Setup
Max Resonances: 10
Hysteresis: 3
Minimum Q Value: 1.00
Smoothing: Low
Channel Number: Control
Profile Settings
Status Frequency Type Acceleration Velocity Displacement
#00 On 5.0 Displacement 0.0755 0.023562 1.500000 3.0 3.0 6.0 6.0 #01 On 57.6 Displacement 10.0001 0.271203 1.500000 3.0 3.0 6.0 6.0 #02 On 2000.0 Acceleration 10.0000 0.007804 0.001242 3.0 3.0 6.0 6.0
Sample N. Visual Inspection
At 25 C (Before and after test)
Lo Alarm
Electrical Test
Hi Alarm
Lo Abort
Hi Abort
1 Passed Passed 2 Passed Passed
13/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
Figure 9. Sinusoidal profile
14/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
ANNEX 2: Contro l Board parts list
Bill Of Materials October 17,2001 11:46:37P age1
Item Quantity Re ference Value Voltage % Footprint
1 6 C1 470nF 16V X7R 0805
C8 470nF 16V X7R 0805 C22 470nF 16V X7R 0805 C40 470nF 16V X7R 0805 C41 470nF 16V X7R 0805 C42 470nF 16V X7R 0805
2 5 C2 100nF Y5V 0603
C3 100nF Y5V 0603 C33 100nF Y5V 0603 C39 100nF Y5V 0603 C46 100nF Y5V 0603
3 6 C4 100pF 0603
C7 100pF 0603
C9 100pF 0603 C18 100pF 0603 C30 100pF 0603 C37 100pF 0603
4 3 C5 470nF 25V Y5V 0805
C19 470nF 25V Y5V 0805 C34 470nF 25V Y5V 0805
5 5 C6 1nF 0603
C20 1nF 0603 C35 1nF 0603 C36 1nF 0603 C45 1nF 0603
6 11 C10 10nF 63V 0603
C11 10nF 63V 0603 C12 10nF 63V 0603 C13 10nF 63V 0603 C23 10nF 63V 0603 C24 10nF 63V 0603 C25 10nF 63V 0603 C26 10nF 63V 0603 C27 10nF 63V 0603 C28 10nF 63V 0603 C29 10nF 63V 0603
7 1 C14 47pF 63V 0603 8 3 C15 470nF Y5V 0805
C21 470nF Y5V 0805 C32 470nF Y5V 0805
15/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
Item Quantity Re fe rence Value Voltage % Footprint
9 3 C16 10nF 0603
C31 10nF 0603 C43 10nF 0603
10 1 C17 2.2nF 0603 11 1 C38 1uF X7R 0805 12 1 C44 1uF 16V Y5V 0805 13 10 D1 BAS16 SOT-23
D2 BAS16 SOT-23
D3 BAS16 SOT-23 D20 BAS16 SOT-23 D21 BAS16 SOT-23 D22 BAS16 SOT-23 D23 BAS16 SOT-23 D24 BAS16 SOT-23 D25 BAS16 SOT-23 D26 BAS16 SOT-23
14 3 IC1 L6386D SO-14
IC2 L6386D SO-14
IC4 L6386D SO-14 15 1 IC3 ST92T141K4M6 SO-34/P1.016 16 2 U1 LM358D SO-8
IC5 LM358D SO-8 17 6 Q1 BC807-25 SOT-23
Q2 BC807-25 SOT-23 Q3 BC807-25 SOT-23 Q4 BC807-25 SOT-23 Q5 BC807-25 SOT-23
Q6 BC807-25 SOT-23 20 1 Q7 BC817-25 SOT-23 21 4 R1 10K 0603
R2 10K 0603
R4 10K 0603
R17 10K 0603
22 12 R3 82R 0603
R15 82R 0603 R24 82R 0603 R36 82R 0603 R46 82R 0603 R81 82R 0603 R82 82R 0603 R83 82R 0603 R84 82R 0603 R85 82R 0603
16/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
Item Quantity Reference Value Voltage % Footprint
R86 82R 0603
23 7 R5 220R 0603
R8 220R 0603
R16 220R 0603 R25 220R 0603 R37 220R 0603 R45 220R 0603
R47 220R 0603 24 1 R6 100R 0603 25 1 R9 0R 0603 26 26 R10 100K 0603
R11 100K 0603
R12 100K 0603
R13 100K 0603
R14 100K 0603
R19 100K 0603
R20 100K 0603
R21 100K 0603
R22 100K 0603
R23 100K 0603
R28 100K 0603
R29 100K 0603
R30 100K 0603
R31 100K 0603
R32 100K 0603
R33 100K 0603
R35 100K 0603
R38 100K 0603
R39 100K 0603
R40 100K 0603
R41 100K 0603
R42 100K 0603
R43 100K 0603
R44 100K 0603
R50 100K 0603 27 2 R27 1K 0603
R18 1K 0603 28 1 R26 2.7K 0603 29 1 R48 820R 1% 0603 30 1 R49 1M 0603 31 1 R51 4.7K 1% 0603 32 1 R52 33.2K 1% 0603 33 1 R53 750R 1% 0603
17/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
Item Quantity Reference Value Voltage % Footprint
34 1 R54 47K 0603 35 2 R56 1.5K 1% 0603
R55 1.5K 1% 0603 36 1 R63 390R 0603 37 1 R80 6.8K 1% 0603 38 6 TP1 TPshort PAD
TP2 TPshort PAD
TP3 TPshort PAD
TP4 TPshort PAD
TP5 TPshort PAD
TP6 TPshort PAD 39 2 TP8 TP0 PAD
TP7 TP0 PAD 40 1 U2 M95040 SO-8 41 1 XT1 CSTCC-MG 5MHz (XT_CSTCCMG)
18/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
4 MECHANICAL DATA: ST92141-PLATFOR M
Figure 10. Mechanical Data
19/21
DESIGNING A LOW COST POWER BOARD F OR ST92141 MOTOR CONTROL MC U ...
5 CONTROL BOARD LAYOUT (ORCAD FILES AVAILABLE)
Figure 11. Microcontroller side
C21
C32
XT1
R35
C31
R32
R42
R41
C27
TP8
R31
R30
R29
R28
R14
R40
R39
R38
R23
C26
C25
C24
C23
U1
C33
R45
D3
R50
R49
C38
C14
R82
ST92141-ENG3
C41
R83
R84
C42
R85
D24D23D22D21
Figure 12. High voltage interfacing side
TP5TP6
C15
R17
Q7
R12
R13
R6R4R2
C2
R1
D2
D1
R22
R21
C3
C13
C12
TP1TP2
TP3TP4
IC3
R34
R33
R11
R10
R44
R43
R20
R19
C10
C11
C29
C28
C44
R54
R56
C46
D26
ST92141-ENG3
TP7
C20
R18
R16
R9
C8
R8
R7
C9
Q3
R86
D25
C34
C36
C35
R48
R51
R46
R47
Q6
C22
IC4
C30
R37
R24
Q5
R36
C37
C43
R80
U2
C39
R63
C19
C17
R26
C16
R27
IC2 IC1
C18
R15
R25
Q4
1
C5
C6
C1
R5
R3
C7
Q2
C4
Q1
20/21
DESIGNING A LOW COST POWER BOARD FOR ST92141 MOTOR CONTROL MCU ...
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2002 STMicroelectronics - All Rights Reserved.
STMicroelectronics Group of Compan i es
http://www.s t. com
Purchase of I
2
C Components by STMicroelectronics conveys a license under the Philips I2C Patent. Rights to use the se components in an
2
C system i s granted pro vided that th e sy stem confo rm s to the I2C Standard Specification as defined by Philips.
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21/21
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