Module power supply, circuit system and electronic equipment

Abstract

The invention provides a module power supply, a circuit system and electronic equipment, which are used for converting a first direct current into a second direct current, and the module power supply comprises a magnetic core structure and a plurality of power supply basic units connected in parallel, the power supply basic unit comprises a planar transformer structure, a first primary side switch structure, a first secondary side switch structure, a second primary side switch structure and a second secondary side switch structure, and the first primary side switch structure and the first secondary side switch structure are arranged on the top surface of the planar transformer structure; the second primary side switch structure and the second secondary side switch structure are arranged on the bottom surface of the planar transformer structure, and the number of groups of planar windings in the planar transformer structure is smaller than or equal to a set threshold value, so that the overall impedance of the module power supply is reduced in equal proportion along with the continuous increase of the parallel number of the power supply basic units; therefore, the loss of the module power supply is effectively optimized.

Description

Technical Field

[0001] The present invention relates to the field of power supplies, and in particular to a module power supply, a circuit system and an electronic device. Background Art

[0002] With the rapid development of artificial intelligence cloud computing centers and new energy vehicles, the industry's requirements for the power density and efficiency of 48V DC-DC module power supplies are getting higher and higher. Although increasing the switching frequency of the module power supply to the MHz level can effectively reduce the size of the module power supply and help improve the power density of the module power supply. However, in high-power application scenarios, the existing module power supply will produce significant losses due to the proximity effect and skin effect of high-frequency and high-current. Therefore, loss optimization design for the module power supply is crucial.

[0003] The prior art generally achieves the loss optimization of the module power supply by optimizing the overall impedance of the transformer in the module power supply. However, the prior art has limitations in optimizing the overall impedance of the transformer, which results in the limitation of the loss optimization of the module power supply. Summary of the invention

[0004] The present invention provides a module power supply, a circuit system and an electronic device to enhance the loss optimization capability of the module power supply.

[0005] In order to solve the above technical problems, the technical solution of the present invention provides a modular power supply for converting a first direct current into a second direct current, and the modular power supply comprises:

[0006] Core structure;

[0007] A plurality of power supply basic units connected in parallel, the plurality of power supply basic units are used together to convert a first direct current input from the outside into a second direct current and output it, the plurality of power supply basic units are stacked in sequence, the power supply basic units surround the magnetic core structure and are penetrated by the magnetic core structure, the power supply basic units each include a planar transformer structure, a first primary switch structure, a first secondary switch structure, a second primary switch structure and a second secondary switch structure, the first primary switch structure and the first secondary switch structure are arranged on the top surface of the planar transformer structure, the second primary switch structure and the second secondary switch structure are arranged on the bottom surface of the planar transformer structure, the planar transformer structure includes a plurality of groups of planar windings connected in parallel, the plurality of groups of planar windings are stacked in sequence, the number of groups of the planar windings is less than or equal to a set threshold, the set threshold is used to characterize the maximum number of planar winding groups that makes the overall impedance of the module power supply decrease proportionally with the increase in the number of parallel power supply basic units.

[0008] Optionally, the set threshold is equal to 2, and the number of groups of the planar winding is 1 or 2.

[0009] Optionally, the set threshold is equal to 3, and the number of groups of the planar windings is 1 or 2 or 3.

[0010] Optionally, each group of the planar windings includes three winding layers connected in parallel, and the three winding layers are stacked in sequence.

[0011] Optionally, each group of the planar windings includes 6 winding layers connected in parallel, and the 6 winding layers are stacked in sequence.

[0012] Optionally, each of the winding layers includes a primary winding and a secondary winding, and the secondary winding is sandwiched between the primary windings.

[0013] Optionally, the first primary switch structure and the second primary switch structure both include a half-bridge switch circuit.

[0014] Optionally, the first secondary switch structure and the second secondary switch structure both include a bridge rectifier circuit.

[0015] The technical solution of the present invention also provides a circuit system, including the module power supply.

[0016] The technical solution of the present invention also provides an electronic device, comprising the circuit system.

[0017] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects:

[0018] The modular power supply provided by the technical solution of the present invention sets a plurality of power basic units connected in parallel, and sets the number of planar winding groups of the planar transformer structure in the power basic unit to be less than or equal to a set threshold. Since the set threshold is used to characterize the maximum number of planar winding groups that makes the overall impedance of the modular power supply decrease in proportion to the increase in the number of parallel power basic units, as the number of parallel power basic units increases, the overall impedance of the modular power supply will decrease in proportion, thereby effectively optimizing the loss of the modular power supply. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a cross-sectional structural schematic diagram of an embodiment of a module power supply;

[0020] Figure 2 yes Figure 1 A 3D schematic diagram of the current path of the secondary winding in the module power supply embodiment shown;

[0021] Figure 3 is a current density distribution diagram of the secondary windings of different winding layers in an embodiment of a modular power supply;

[0022] Figure 4It is a simplified cross-sectional structural diagram of a module power supply provided by an embodiment of the present invention;

[0023] Figure 5 A waveform diagram showing the change in the loss of the module power supply provided by the embodiment of the present invention as the number of power supply basic units connected in parallel changes. DETAILED DESCRIPTION

[0024] As described in the background art, the prior art has limitations in optimizing the overall impedance of the transformer, which results in limited loss optimization of the module power supply.

[0025] The following takes an embodiment of a module power supply as an example and describes in detail the reasons why the technical personnel of the present invention found the problems existing in the existing module power supply in combination with the accompanying drawings:

[0026] Figure 1 is a schematic cross-sectional structure diagram of a module power supply embodiment, Figure 2 yes Figure 1 A 3D schematic diagram of the current path of the secondary winding in the module power supply embodiment is shown.

[0027] Please refer to Figure 1 and Figure 2 The module power supply includes: a switch device 100 and a synchronous rectification device 200 arranged at both the top and bottom layers of the power supply, a plurality of transformer winding layers 300 arranged in the middle of the power supply, and a magnetic core structure 400 arranged in the plurality of transformer winding layers 300.

[0028] The working process of the module power supply is as follows:

[0029] The direct current enters the primary current path vertically from the switch devices 100 arranged at the top and bottom layers of the power supply, and is converted into a corresponding alternating current. The primary current path is composed of the current through holes of the primary winding in each transformer winding layer 300. The alternating current is transmitted to the primary winding of each transformer winding layer 300 through the primary current path. The alternating current in the primary winding is transmitted to the corresponding secondary winding through the magnetic core structure 400, and is transmitted to the synchronous rectifier device 200 at the top layer of the power supply and the synchronous rectifier device 200 at the bottom layer of the power supply through the secondary current path. The secondary current path is composed of the current through holes of the secondary winding in each transformer winding layer 300. The alternating current passing through the synchronous rectifier device 200 is converted into a corresponding direct current and output, and returns to the corresponding secondary winding through the secondary current path to form a current loop.

[0030] Taking a 48V module power supply as an example, if the output power of the module power supply is 800W, the output current of the module power supply will be as high as about 120A. Because of the proximity effect and skin effect of high-frequency current, the module power supply will produce significant losses. Among the total losses of the module power supply, the loss of the transformer generally accounts for more than half, so the loss optimization design of the transformer is a key technology to improve the performance of the power supply.

[0031] A common method for optimizing transformer losses is to optimize the overall impedance of the transformer winding layer 300. Figure 1 The embodiment shown generally increases the number of transformer winding layers 300 connected in parallel, that is, more transformer winding layers 300 are connected in parallel to reduce the overall impedance of the transformer winding layers 300, thereby reducing the loss of the transformer. However, the problem with this solution is that:

[0032] Please refer to Figure 2 As the number of transformer winding layers 300 connected in parallel increases, the distance between the transformer winding layer 300 located in the middle area and the top and bottom layers will increase accordingly, thereby increasing the primary current input distance and the secondary current rectification distance of the transformer winding layer 300 in the middle area, thereby causing the AC impedance of the transformer winding layer 300 in the middle area to become larger and larger. Therefore, in the process of increasing the number of transformer winding layers 300 connected in parallel, the rate of decrease of the overall impedance of the transformer winding layer 300 is not an approximately proportional trend, but is becoming slower and slower, thereby limiting the loss optimization of the transformer, and further limiting the loss optimization of the module power supply.

[0033] In addition to the qualitative analysis of AC impedance, the inventors also conducted actual current density simulation. Figure 3 The specific simulation results are explained.

[0034] Please refer to Figure 3 , Figure 3 The color table on the left is used to indicate the intensity of current density, and the intensity of current density increases from purple at the bottom to red at the top. Figure 3 The color distribution of different winding layers on the right side shows that the current density in the first secondary winding layer at the top layer and the sixth secondary winding layer at the bottom layer is the largest, but as the number of layers of the secondary winding approaches the middle area, the current density in the secondary winding is also decreasing. Among them, the current density in the third secondary winding layer and the fourth secondary winding layer is the smallest. Therefore, as the number of layers of the transformer winding layer 300 increases, the current density of the secondary winding closer to the middle area is smaller, that is, the contribution to improving the overall output power of the module power supply is also smaller.

[0035] It should be noted that the loss optimization problem existing in the above-mentioned module power supply embodiment was discovered by the inventor of this application after a lot of research and experiments. The discovery of this problem is the prerequisite for the successful research of the present application scheme; therefore, the discovery of this problem itself is an innovation in this field, which is inseparable from the technical solution of this application. As a whole, it is a major technological breakthrough in this field, with significant creativity and value.

[0036] In view of this, an embodiment of the present invention provides a new module power supply, which is used to convert a first direct current into a second direct current, so as to effectively optimize the loss of the module power supply.

[0037] Figure 4 It is a simplified cross-sectional structural diagram of a module power supply provided by an embodiment of the present invention.

[0038] Please refer to Figure 4 , the module power supply provided by the embodiment of the present invention includes:

[0039] Magnetic core structure 10;

[0040] A plurality of power supply basic units 20 connected in parallel, each power supply basic unit 20 surrounds the magnetic core structure 10 and is penetrated by the magnetic core structure 10, the plurality of power supply basic units 20 are used together to convert the first DC current input from the external input into the second DC current and output it, each power supply basic unit 20 includes: a planar transformer structure 21, a first primary switch structure 22, a first secondary switch structure 23, a second primary switch structure 24 and a second secondary switch structure 25, the first primary switch structure 22 and the first secondary switch structure 23 are arranged on the top surface of the planar transformer structure 21, the second primary switch structure 24 and the second secondary switch structure 25 are arranged on the bottom surface of the planar transformer structure 21, the planar transformer structure 21 includes a plurality of groups of planar windings connected in parallel, the plurality of groups of planar windings are stacked in sequence, the number of groups of the planar windings is less than or equal to a set threshold, and the set threshold is used to characterize the maximum number of planar winding groups that makes the overall impedance of the module power supply decrease proportionally with the increase in the number of the power supply basic units 20 in parallel.

[0041] The direct current input to the power supply basic unit 20 is converted into a corresponding alternating current by the first primary switch structure 22 and the second primary switch structure 24, and flows through the top and bottom of the planar transformer structure 21 to the primary winding in the planar winding through the vias. The alternating current in the primary winding is transformed to the secondary winding in the planar winding according to the alternating electric field provided by the magnetic core structure 10, and flows through the first secondary switch structure 23 and the second secondary switch structure 25 through the vias.

[0042] The embodiment of the present invention divides the modular power supply into a plurality of power supply basic units 20, each of which includes: a planar transformer structure 21, a first primary switch structure 22, a first secondary switch structure 23, a second primary switch structure 24, and a second secondary switch structure 25. Therefore, each power supply basic unit 20 can be regarded as an independent small modular power supply. In each power supply basic unit 20, the planar transformer structure 21 is only provided with a planar winding number less than or equal to a set threshold number, and the set threshold is used to characterize the maximum number of planar winding groups that makes the overall impedance of the modular power supply decrease proportionally with the increase in the number of parallel power supply basic units 20.

[0043] Taking the planar transformer structure 21 as an example, in which only one or two planar windings are provided, since the number of planar windings provided is small, the distance from the primary switch structure at the top and bottom to the planar winding through the vias of the AC current, and the distance from the planar winding to the secondary switch structure at the top and bottom through the vias of the AC current are both short, thus having a smaller AC impedance. That is, the modular power supply of this embodiment first sets the number of planar windings in a single power basic unit 20 to be less than or equal to the set threshold value, so as to greatly reduce the AC loss of the single power basic unit 20.

[0044] In order to improve the output power of the module power supply and optimize the overall impedance of the module power supply, the module power supply is provided with a plurality of the power supply basic units 20 connected in parallel to integrate and output the DC current output by each power supply basic unit 20. Since the AC impedance of each power supply basic unit 20 is fixed and the AC impedance is small, connecting a plurality of the power supply basic units 20 in parallel can effectively reduce the overall impedance of the module power supply. And as the number of the power supply basic units 20 connected in parallel increases, the overall impedance of the module power supply will also decrease in proportion, which not only achieves a good current sharing effect between the power supply basic units 20, but also effectively optimizes the loss problem of the module power supply, thereby improving the output power of the module power supply.

[0045] Of course, the specific number of planar windings in each power basic unit 20 can be set according to demand and is not limited here. For example, the set threshold can be set to 2, and the number of planar windings is 1 or 2. Or the set threshold is equal to 3, and the number of planar windings is 1, 2 or 3.

[0046] It should be noted that Figure 4Due to the obstruction, the bottom and top surfaces of adjacent power supply basic units do not simultaneously display the first primary switch structure or the second primary switch structure, nor do they simultaneously display the first secondary switch structure or the second secondary switch structure. Of course, adjacent power supply basic units can also share the first primary switch structure or the second primary switch structure, and share the first secondary switch structure or the second secondary switch structure, but this will bring additional current stress and additional control costs to the module power supply.

[0047] In order to further illustrate that the modular power supply provided by the embodiment of the present invention achieves better loss optimization as the number of parallel power basic units 20 increases, the following will illustrate the change trend of the loss of the modular power supply provided by the embodiment of the present invention as the number of parallel power basic units increases.

[0048] Figure 5 The loss of the module power supply provided by the embodiment of the present invention varies with the number of power supply basic units connected in parallel.

[0049] Please refer to Figure 5 ,Depend on Figure 5 It can be seen that as the number of power basic units connected in parallel increases, the loss of the module power supply decreases in an inversely proportional trend. This shows that its impedance decreases approximately linearly with the increase in the number of parallel units. Therefore, the power basic unit provided by the embodiment of the present invention and the increase in the number of parallel power basic units can effectively optimize the loss of the module power supply.

[0050] In order to make the above-mentioned purposes, features and beneficial effects of the present invention more obvious and understandable, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in the field without creative work belong to the scope of protection of the present invention. The terms "first", "second", "third", "fourth", etc. (if any) in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present invention described here can be implemented in an order other than those illustrated or described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0051] As a specific implementation, usually each group of the planar windings includes three winding layers connected in parallel or six winding layers connected in parallel, which depends on the specific application and is not limited here.

[0052] The winding layers in the planar winding are stacked in sequence. The winding layers include a primary winding and a secondary winding, and the secondary winding is sandwiched in the primary winding according to a sandwich winding method. Of course, the specific winding methods of the primary winding and the secondary winding can be selected according to needs and are not limited here.

[0053] As a specific implementation, the number of parallel power supply basic units can be set to more than 20, and it can be seen from the above description that the advantage of the module power supply provided by the embodiment of the present invention in loss optimization will continue to increase with the increase in the number of parallel power supply basic units. Of course, the number of parallel power supply basic units can be set according to the actual output power of the module power supply, which is not limited here.

[0054] As a specific implementation, the first primary switch structure and the second primary switch structure are specifically half-bridge switch circuits, which are used to convert the input DC current into a corresponding AC current. Since the full-bridge switch circuit is a conventional technical means in this field, its specific circuit structure and working principle are not described in detail. Among them, the switch tube in the half-bridge switch circuit can be selected from any one of a silicon-based MOS tube, a gallium nitride tube and a silicon carbide tube. Of course, in addition to the half-bridge switch circuit, the primary switch substructure can also select other circuits with a switch rectification function, which is not limited here.

[0055] As a specific implementation, the first secondary switch structure and the second secondary switch structure are specifically a bridge rectifier circuit, which is used to convert the input AC current into a corresponding DC current and output it. Since the bridge rectifier circuit is a conventional technical means in this field, its specific circuit structure and working principle are not described in detail. Among them, the switch tube in the bridge rectifier circuit can be selected from any one of a silicon-based MOS tube, a gallium nitride tube and a silicon carbide tube. Of course, in addition to the bridge rectifier circuit, the secondary switch substructure can also select other circuits with a switch rectification function, which is not limited here.

[0056] In summary, the modular power supply provided by the embodiment of the present invention first sets the number of planar winding groups in a single power basic unit to be less than or equal to a set threshold value, so as to greatly reduce the AC loss of a single power basic unit, and then sets a plurality of the power basic units to be connected in parallel, so as to integrate and output the DC current output by each power basic unit, thereby effectively reducing the overall impedance of the modular power supply. And as the number of the power basic units in parallel increases, the overall impedance of the modular power supply will also decrease in proportion, which not only achieves a good current sharing effect between the power basic units, but also effectively optimizes the loss problem of the modular power supply, thereby increasing the output power of the modular power supply.

[0057] An embodiment of the present invention further provides a circuit system, comprising the module power supply provided by the embodiment of the present invention.

[0058] An embodiment of the present invention further provides an electronic device, comprising the circuit system provided by the embodiment of the present invention.

[0059] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A module power supply, characterized in that: For converting a first direct current into a second direct current, the module power supply comprises: Core structure; A plurality of power supply basic units connected in parallel, the plurality of power supply basic units are used together to convert a first direct current input from the outside into a second direct current and output it, the plurality of power supply basic units are stacked in sequence, the power supply basic units surround the magnetic core structure and are penetrated by the magnetic core structure, the power supply basic units each include a planar transformer structure, a first primary switch structure, a first secondary switch structure, a second primary switch structure and a second secondary switch structure, the first primary switch structure and the first secondary switch structure are arranged on the top surface of the planar transformer structure, the second primary switch structure and the second secondary switch structure are arranged on the bottom surface of the planar transformer structure, the planar transformer structure includes a plurality of groups of planar windings connected in parallel, the plurality of groups of planar windings are stacked in sequence, the number of groups of the planar windings is less than or equal to a set threshold, the set threshold is used to characterize the maximum number of planar winding groups that makes the overall impedance of the module power supply decrease proportionally with the increase in the number of parallel power supply basic units.

2. The modular power supply according to claim 1, characterized in that: The set threshold is equal to 2, and the number of groups of the planar winding is 1 or 2.

3. The modular power supply according to claim 1, characterized in that: The set threshold is equal to 3, and the number of groups of the planar winding is 1, 2 or 3.

4. The modular power supply according to claim 1, characterized in that: Each group of the planar windings includes three winding layers connected in parallel, and the three winding layers are stacked in sequence.

5. The modular power supply according to claim 1, characterized in that: Each group of the planar windings includes six winding layers connected in parallel, and the six winding layers are stacked in sequence.

6. The modular power supply according to claim 4 or 5, characterized in that: Each of the winding layers includes a primary winding and a secondary winding, and the secondary winding is sandwiched between the primary windings.

7. The modular power supply according to claim 1, characterized in that: The first primary switch structure and the second primary switch structure both include a half-bridge switch circuit.

8. The modular power supply according to claim 1 or 7, characterized in that: The first secondary switch structure and the second secondary switch structure both include a bridge rectifier circuit.

9. A circuit system, characterized in that: A module power supply comprising any one of claims 1 to 8.

10. An electronic device, characterized in that: A circuit system comprising the circuit system of claim 9.

Images