Power factor correction module, controller and electrical appliance

Abstract

The application discloses a power factor correction module, a controller and an electrical equipment, and relates to the technical field of power factor correction. The power factor correction module comprises a substrate, a rectification circuit, a switching circuit, a direct current output terminal, a voltage transformation input terminal and a high-voltage access terminal. The rectification circuit and the switching circuit are formed on the substrate. The direct current output terminal is electrically connected with the rectification circuit. The voltage transformation input terminal is electrically connected with the switching circuit. The high-voltage access terminal is connected with the output terminal of the switching circuit. The high-voltage access terminal is used for accessing an external load. The direct current output terminal and the voltage transformation input terminal are respectively used for accessing two ends of an external inductor, so that the external inductor and the switching circuit form a PFC loop when the external inductor is accessed. In this way, by integrating the rectification circuit and the switching circuit on the same substrate, the number of elements of the rectification circuit and the PFC circuit is reduced, the volume of the rectification circuit and the PFC circuit is reduced, and the installation convenience of the rectification circuit and the FPC circuit is improved.

Description

Technical Field

[0001] This application relates to the field of power factor correction technology, and in particular to a power factor correction module, controller and electrical equipment. Background Technology

[0002] With the widespread use of electronic devices, harmonic pollution of the power grid is becoming increasingly severe. Currently, converting AC to DC power from the power grid using rectifier circuits and employing power factor correction (PFC) technology can effectively reduce harmonic components, improve the power factor, thereby reducing energy consumption, decreasing the size and weight of power supply equipment, reducing conductor cross-sectional area, and reducing radiated and conducted interference from power supply equipment. However, in implementing the above solutions, the circuit components used are mostly independent components, resulting in a large number of components and a bulky overall circuit, which is not conducive to wiring and installation. Summary of the Invention

[0003] The main purpose of this application is to provide a power factor correction module, controller and electrical equipment, which aims to improve the ease of installation of rectifier circuits and FPC circuits.

[0004] To achieve the above objectives, this application provides a power factor correction module, comprising:

[0005] Substrate;

[0006] The rectifier circuit is formed on the substrate;

[0007] The switching circuit is formed on the substrate;

[0008] The DC output terminal is electrically connected to the rectifier circuit.

[0009] The transformer input terminal is electrically connected to the switching circuit.

[0010] High-voltage access terminal: The high-voltage access terminal is connected to the output terminal of the switching circuit and is used to connect to an external load.

[0011] The DC output terminal and the transformer input terminal are respectively used to connect to the two ends of an external inductor, so that when an external inductor is connected, the external inductor and the switching circuit form a PFC loop.

[0012] In one embodiment, the substrate has a first side surface on which both the rectifier circuit and the switching circuit are formed.

[0013] In one embodiment, the power factor correction module further includes:

[0014] The package housing covers the substrate to encapsulate the rectifier circuit and the switching circuit within the package housing.

[0015] In one embodiment, the substrate further has a second side surface disposed opposite to the first side surface, the second side surface being exposed outside the package housing.

[0016] In one embodiment, the power factor correction module further includes:

[0017] Multiple pins are connected to the DC output terminal, transformer input terminal, and high voltage access terminal, respectively.

[0018] In one embodiment, there are multiple pins connected to the DC output terminal and / or the transformer input terminal and / or the high voltage access terminal, and these multiple pins are connected in parallel.

[0019] In one embodiment, the DC output terminal includes: a first DC output terminal and a second DC output terminal, the first DC output terminal and the second DC output terminal being used to output DC power formed by rectifying AC power through a rectifier circuit;

[0020] The power factor correction module also includes:

[0021] The first AC input terminal and the second AC input terminal are electrically connected to the rectifier circuit, respectively. The first AC input terminal and the second AC input terminal are used to connect AC power so as to output AC power to the rectifier circuit.

[0022] The grounding terminal is electrically connected to the switching circuit and is used to ground the switching circuit.

[0023] The control signal input terminal is electrically connected to the switching circuit and is used to input control signals to control the conduction state of the switching circuit.

[0024] The second DC output terminal, the grounding terminal, and the control signal input terminal are arranged sequentially on the first side of the power factor correction module; the first AC input terminal, the first DC output terminal, the transformer input terminal, and the high voltage input terminal are arranged sequentially on the second side of the power factor correction module.

[0025] In one embodiment, the second AC input terminal is disposed on the first side and on the side of the second DC output terminal away from the ground terminal.

[0026] In one embodiment, the distance between the second AC input terminal and the second DC output terminal is greater than the distance between the second DC output terminal and the ground terminal, and the distance between the second AC input terminal and the second DC output terminal is greater than the distance between the ground terminal and the control signal access terminal.

[0027] In one embodiment, the power factor correction module further includes:

[0028] First temperature detection terminal;

[0029] Second temperature detection terminal;

[0030] A temperature detection circuit is formed on the substrate; the temperature detection circuit is electrically connected to the first temperature detection terminal and the second temperature detection terminal respectively; the temperature detection circuit is used to detect the temperature of the power factor correction module.

[0031] This application also proposes a controller, which includes an inductor and a power factor correction module, wherein the two ends of the inductor are connected to a DC output terminal and a transformer input terminal, respectively.

[0032] In one embodiment, there are multiple power factor correction modules connected in parallel.

[0033] This application also proposes an electrical device, which includes a power factor correction module and / or a controller.

[0034] The power factor correction module of this application includes a substrate, a rectifier circuit, a switching circuit, a DC output terminal, a transformer input terminal, and a high-voltage input terminal. The rectifier circuit and the switching circuit are formed on the substrate. The DC output terminal is electrically connected to the rectifier circuit, the transformer input terminal is electrically connected to the switching circuit, and the high-voltage input terminal is connected to the output terminal of the switching circuit. The high-voltage input terminal is used to connect an external load. The DC output terminal and the transformer input terminal are respectively used to connect to the two ends of an external inductor, so that when an external inductor is connected, the external inductor and the switching circuit form a PFC loop to adjust the DC power output of the high-voltage input terminal, thereby adjusting the power factor of the external load. In this way, by integrating the rectifier circuit and the switching circuit on the same substrate, the number of components in the rectifier circuit and the PFC circuit are reduced, the size of the rectifier circuit and the PFC circuit is reduced, and the installation convenience of the rectifier circuit and the FPC circuit is improved. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the circuit structure of an embodiment of the power factor correction module of this application;

[0037] Figure 2 This is a schematic diagram of the circuit structure of another embodiment of the power factor correction module of this application;

[0038] Figure 3A circuit structure diagram for yet another embodiment of the power factor correction module of this application;

[0039] Figure 4 A circuit structure diagram of yet another embodiment of the power factor correction module of this application;

[0040] Figure 5 A schematic diagram of the circuit structure of another embodiment of the power factor correction module of this application is provided;

[0041] Figure 6 This is a schematic diagram showing the correspondence between the NTC detection temperature and the IGBT junction temperature, provided for an embodiment of the power factor correction module of this application.

[0042] Explanation of icon numbers:

[0043] 100. Power factor correction module; 10. Rectifier circuit; 20. Switching circuit; DC, DC output terminal; PFC, transformer input terminal; P, high voltage input terminal; AC1, first AC input terminal; AC2, second AC input terminal; DC+, first DC output terminal; DC-, second DC output terminal; 101, first diode; 102, second diode; 103, third diode; 104, fourth diode; GND, ground terminal; G, control signal input terminal; NTC1, first temperature detection terminal; NTC2, second temperature detection terminal; 30, temperature detection circuit; 301, thermistor; 401, inductor; AC, alternating current; RL, external load.

[0044] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0045] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0046] It should be noted that if the embodiments of this application involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0047] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0048] With the widespread use of electronic devices, harmonic pollution of the power grid is becoming increasingly severe. Currently, converting the AC power from the power grid to DC power through a rectifier circuit 10 and employing power factor correction (PFC) technology can effectively reduce harmonic components, improve the power factor, thereby reducing energy consumption, decreasing the size and weight of power supply equipment, reducing conductor cross-sectional area, and reducing radiation and conducted interference from power supply equipment. However, in implementing the above solution, the circuit components used are mostly independent components, resulting in a large number of overall circuit components and a bulky size, which is not conducive to wiring and installation.

[0049] Based on the above problems, this application proposes a power factor correction module 100, with reference to... Figure 1 The power factor correction module 100 of this application includes a substrate, a rectifier circuit 10, a switching circuit 20, a DC output terminal DC, a transformer input terminal PFC, and a high-voltage access terminal P. The rectifier circuit 10 and the switching circuit 20 are formed on the substrate. The DC output terminal DC is electrically connected to the rectifier circuit 10, the transformer input terminal PFC is electrically connected to the switching circuit 20, and the high-voltage access terminal P is connected to the output terminal of the switching circuit 20. The high-voltage access terminal P is used to connect an external load RL. The DC output terminal DC and the transformer input terminal PFC are respectively used to connect to the two ends of the external inductor RL, so that when an external inductor 401 is connected, the external inductor 401 and the switching circuit 20 form a PFC circuit to adjust the DC power output of the high-voltage access terminal P, thereby adjusting the power factor of the external load.

[0050] In this embodiment, the rectifier circuit 10 can be a unidirectional half-wave rectifier circuit formed by a single diode, a unidirectional full-wave rectifier circuit composed of a center-tapped transformer and two diodes, a rectifier bridge composed of four diodes, or a controllable rectifier circuit composed of silicon controlled rectifiers, thyristors, or other controllable switching devices, etc., used to rectify alternating current (AC) into direct current (DC). The specific type of rectifier circuit 10 can be selected according to actual application requirements and is not limited here. In this embodiment, the rectifier circuit 10 can be formed on the substrate by mounting one or more bare chips corresponding to the required components onto the substrate and electrically connecting multiple bare chips to each other. Alternatively, physical vapor deposition (PVD) or chemical vapor deposition (CVD) techniques can be used to deposit the necessary metal or insulating layers on the alumina substrate. Then, the required bare chips are cut from the fabricated wafer and fixed to the designated locations on the substrate using conductive or non-conductive adhesive. Subsequently, wire bonding is performed using fine metal wires (such as gold wires) to electrically connect the pads of the bare chips to the metal layers or pins on the substrate. Next, interconnect lines are defined on the metal layers using photolithography and etching techniques to ensure electrical connections between the individual bare chips, so that the rectifier circuit 10 is formed on the substrate.

[0051] In this embodiment, the switching circuit 20 can employ switching devices such as MOSFETs, IGBTs, and diodes, which can be connected to the inductor 401 to form a PFC topology, thereby achieving power factor correction of the AC input voltage. The switching circuit 20 can also receive control signals to adjust the switching state of the switching devices, thereby controlling the magnitude and direction of the current in the inductor 401, achieving stability of the output DC voltage and regulation of the power factor. In this embodiment, the switching circuit 20 can also be formed on the substrate by mounting one or more bare chips corresponding to the required components (such as MOSFETs, IGBTs, or diodes) onto the substrate and electrically connecting multiple bare chips to each other. The specific process is the same as in the above embodiment and will not be repeated here.

[0052] In this embodiment, when an inductor 401 is connected between the DC output terminal (DC) and the PFC transformer input terminal (PFC), the inductor 401 and the switching circuit 20 work together to form a PFC loop. This loop effectively reduces the harmonic components of the input current, improves the power factor of the power grid, reduces harmonic pollution, and reduces energy waste. Since the switching circuit 20 and the rectifier circuit 10 are integrated on the same substrate to form an integrated power factor correction module, compared to using discrete components to construct the rectifier and switching circuits, the number of components in the rectifier circuit 10 and the PFC circuit on the circuit board is reduced, which helps to reduce the size of the circuit board. When the circuit board is used in electrical equipment, it is easier to install and promotes the miniaturization and portability of electrical equipment. Furthermore, during the installation of the power factor correction module 100, it is not necessary to wire each component in the rectifier circuit 10 and the PFC circuit separately. Only the pins corresponding to the terminals of the power factor correction module need to be connected to complete the installation of the entire module, simplifying the installation process and improving ease of installation.

[0053] In one feasible embodiment, the substrate has a first side surface on which both the rectifier circuit 10 and the switching circuit 20 are formed. The substrate can be made of a material with good thermal conductivity (e.g., alumina) to ensure that the heat generated by the power factor correction module 100 during operation can be effectively dissipated, avoiding performance degradation or damage due to overheating. By placing the rectifier circuit 10 and the switching circuit 20 on the same side surface, the wiring and assembly process can be simplified, the risk of failure due to improper wiring can be reduced, and subsequent packaging of the power factor correction module 100 is also beneficial.

[0054] In one feasible implementation, the power factor correction module further includes a housing encapsulated on a substrate to encapsulate the rectifier circuit and the switching circuit within the housing. In this embodiment, the housing may be made of an insulating material (e.g., epoxy resin-based) to ensure the safe isolation of the internal circuitry and prevent external environmental influences. Furthermore, the housing design can consider waterproofing and dustproofing requirements to adapt to various harsh operating environments. By integrating the rectifier circuit 10 and the switching circuit 20 into this housing, the internal circuitry can be effectively protected from external interference, while facilitating the installation and maintenance of the power factor correction module 100. Additionally, it reduces the number of components in the rectifier circuit 10 and the PFC circuit, shrinks their size, and improves the ease of installation. Overall, this not only improves the module's stability, safety, and ease of installation but also enhances its reliability and durability in industrial applications.

[0055] In one feasible embodiment, the substrate further has a second side surface disposed opposite to the first side surface, the second side surface being exposed outside the package housing. This allows the second side surface of the substrate to directly contact the external environment, thereby accelerating heat dissipation through natural convection or forced air cooling, effectively enhancing the heat dissipation effect of the power factor correction module 100.

[0056] In one feasible implementation, the power factor correction module further includes multiple pins, which are respectively connected to the DC output terminal DC, the transformer input terminal PFC, and the high voltage access terminal P.

[0057] In this embodiment, the pins can be made of materials such as copper or copper alloys to ensure good conductivity and sufficient mechanical strength. Connecting multiple pins through the DC output terminal (DC), the transformer input terminal (PFC), and the high-voltage access terminal (P) simplifies the connection process between the module and external circuits, reduces installation errors, and improves the stability of the overall circuit system.

[0058] In one feasible implementation, the number of pins connected to the DC output terminal DC and / or the transformer input terminal PFC and / or the high voltage access terminal P is multiple, and the multiple pins are arranged in parallel.

[0059] In this embodiment, by connecting the DC output terminal (DC) and / or the transformer input terminal (PFC) and / or the high-voltage access terminal (P) to multiple pins, not only is the current flow capability improved, enabling the power factor correction module 100 to connect more flexibly and communicate more quickly with external devices or systems, but the heat dissipation capacity of each terminal is also enhanced. This allows the power factor correction module 100 to improve heat dissipation efficiency when operating under high load by increasing the contact area between the terminal and the external device, thereby avoiding performance degradation or damage due to overheating. Furthermore, the multiple-pin design also improves the electrical connection reliability of the module and reduces the risk of failure due to poor contact.

[0060] In one feasible implementation, reference is made to... Figure 2 The power factor correction module 100 also includes a first AC input terminal AC1 and a second AC input terminal AC2, which are used to connect AC power. The rectifier circuit 10 includes a diode bridge, which is connected to the first AC input terminal AC1 and the second AC input terminal AC2 respectively, and is used to convert the AC power connected to the first AC input terminal AC1 and the second AC input terminal AC2 into DC power, which is then output through the DC output terminal DC.

[0061] In this embodiment, the diode bridge may include two diodes, which are respectively connected to the first AC input terminal AC1 and the second AC input terminal AC2, forming a simple rectifier bridge structure. Furthermore, the diode bridge may also include four diodes connected in pairs, with the output terminals connected to the DC output terminal DC, converting AC to DC to achieve full-wave rectification. The diode bridge effectively converts AC to DC and provides a more stable DC output, laying the foundation for subsequent power factor correction.

[0062] In one feasible implementation, the power factor correction module further includes a first filter circuit. This first filter circuit can also be formed on the substrate by mounting one or more bare chips corresponding to the required components onto the substrate and electrically connecting multiple bare chips to each other. The specific process is the same as described in the above embodiment and will not be repeated here. The first filter circuit is located between the output terminal of the diode bridge and the DC output terminal to filter out high-frequency noise and ripple generated during rectification, ensuring the stability of the output DC power. This filter circuit can consist of capacitors and / or resistors, effectively improving the quality of the DC power and providing better input conditions for the power factor correction module 100.

[0063] In one feasible implementation, refer to Figure 2 The DC output terminal includes a first DC output terminal DC+ and a second DC output terminal DC-. Both DC+ and DC- are used to output DC power rectified from AC power by the rectifier circuit 10. The first DC output terminal DC+ is the positive terminal of the output DC power, and the second DC output terminal DC- is the negative terminal. The power factor correction module also includes a first AC input terminal AC1 and a second AC input terminal AC2. Both AC1 and AC2 are electrically connected to the rectifier circuit 10. These terminals are used to connect AC power to the rectifier circuit 10 and output the AC power.

[0064] In this embodiment, the rectifier circuit specifically includes a first diode 101, a second diode 102, a third diode 103, and a fourth transistor. The anode of the first diode 101 is electrically connected to the second DC output terminal DC-, and the cathode of the first diode 101 is electrically connected to the first AC input terminal AC1. The anode of the second diode 102 is electrically connected to the second DC output terminal DC-, and the cathode of the second diode 102 is electrically connected to the second AC input terminal AC2. The anode of the third diode 103 is electrically connected to the second AC input terminal AC2, and the cathode of the third diode 103 is electrically connected to the first DC output terminal DC+. The anode of the fourth diode 104 is electrically connected to the first AC input terminal AC1, and the cathode of the fourth diode 104 is electrically connected to the first DC output terminal DC+. The interconnection of the first diode 101, the second diode 102, the third diode 103, and the fourth diode 104 forms a complete rectifier bridge structure, ensuring that the input AC power can be effectively converted into DC power regardless of whether it is in the forward or reverse direction. In addition, it can improve rectification efficiency, reduce energy loss, and thus further enhance the performance of the entire power factor correction module 100.

[0065] In one feasible implementation, the power factor correction module 100 may further include a second filter circuit. This second filter circuit can also be formed on the substrate by mounting one or more bare chips corresponding to the required components (such as MOSFETs, IGBTs, or diodes) onto the substrate and electrically connecting multiple bare chips to each other. The specific process is the same as described in the above embodiments and will not be repeated here. This second filter circuit is located between the high-voltage input terminal P and the external load RL to further filter out high-frequency noise and ripple generated by the PFC circuit, ensuring the DC power quality at the load end. The second filter circuit can also consist of capacitors and / or resistors to improve the stability of the output DC power and ensure that the output of the power factor correction module 100 meets the load requirements.

[0066] In one feasible implementation, refer to Figure 2 The power factor correction module 100 also includes a ground terminal GND and a control signal input terminal G. The ground terminal GND is electrically connected to the switching circuit 20 to ground the switching circuit 20. The control signal input terminal G is electrically connected to the switching circuit 20 to receive a control signal to control the conduction state of the switching circuit 20. Specifically, the switching circuit 20 includes a switching transistor and a diode. The first terminal of the switching transistor is electrically connected to the transformer input terminal PFC, the second terminal of the switching transistor is electrically connected to the ground terminal GND, and the gate of the switching transistor is electrically connected to the control signal input terminal G. The anode of the diode is electrically connected to the transformer input terminal PFC, and the cathode of the diode is electrically connected to the high voltage input terminal P.

[0067] In this embodiment, a boost PFC topology can be formed through the switching transistor, diode, and inductor 401 connected between the DC output terminal and the PFC transformer input terminal. The control signal connected to the control signal input terminal can be a PWM signal. Under the action of the PWM control signal, the switching transistor periodically turns on and off, thereby adjusting the current of inductor 401 and achieving stable control of the output voltage. By adjusting the duty cycle of the PWM signal, the phase and shape of the voltage and current waveforms of the DC power output from the high-voltage input terminal P after inversion by the subsequent circuit can be made consistent with the input AC waveform, thereby correcting the power factor of the external load RL.

[0068] In one feasible implementation, refer to Figure 2 The second DC output terminal DC-, the ground terminal GND, and the control signal input terminal G are arranged sequentially on the first side of the power factor correction module 100; the first AC input terminal AC1, the first DC output terminal DC+, the transformer input terminal PFC, and the high voltage input terminal P are arranged sequentially on the second side of the power factor correction module 100.

[0069] It is understandable that the second DC output terminal DC-, the ground terminal GND, and the control signal input terminal G are all connected to or output with lower voltages, while the first AC input terminal AC1, the first DC output terminal DC+, the transformer input terminal PFC, and the high-voltage input terminal P are all connected to or output with higher voltages. Therefore, arranging the second DC output terminal DC-, the ground terminal GND, and the control signal input terminal G on one side of the power factor correction module 100, and arranging the first AC input terminal AC1, the first DC output terminal DC+, the transformer input terminal PFC, and the high-voltage input terminal P on the other side of the power factor correction module 100, that is, separating the high-voltage and low-voltage terminals, can effectively reduce electromagnetic interference between the high-voltage and low-voltage terminals and improve the stability and safety of the power factor correction module 100.

[0070] In one feasible implementation, the second AC input terminal AC2 is disposed on the first side and on the side of the second DC output terminal DC away from the ground terminal. It is understood that since the second AC input terminal AC2 and the first AC input terminal AC1 are respectively used to connect to the two input terminals of AC power, the second AC input terminal AC2 is disposed on the first side and on the side of the second DC output terminal DC away from the ground terminal. That is, the second AC input terminal AC2 and the first AC input terminal AC1 are respectively disposed on both sides of the power factor correction module 100. This is to reduce the parasitic inductance 401 between the second AC input terminal AC2 and the first AC input terminal AC1 and to improve the electrical isolation effect between them.

[0071] In one feasible implementation, the distance between the second AC input terminal AC2 and the second DC output terminal DC- is greater than the distance between the second DC output terminal DC- and the ground terminal GND, and the distance between the second AC input terminal AC2 and the second DC output terminal DC- is greater than the distance between the ground terminal GND and the control signal access terminal G.

[0072] In this embodiment, since both the second AC input terminal AC2 and the first AC input terminal AC1 are high-voltage terminals, the second AC input terminal AC2 is positioned on the same side as the second DC output terminal DC-, the ground terminal GND, and the control signal access terminal G. Furthermore, the distance between the second AC input terminal AC2 and the second DC output terminal DC- is greater than the distance between the second DC output terminal DC- and the ground terminal GND, and the distance between the second AC input terminal AC2 and the second DC output terminal DC- is greater than the distance between the ground terminal GND and the control signal access terminal G. This further optimizes the internal layout of the module, reduces electromagnetic interference between high-voltage and low-voltage terminals, and improves the stability and safety of the power factor correction module 100.

[0073] In one feasible implementation, the first AC input terminal AC1, the second AC input terminal AC2, the ground terminal GND, the control signal input terminal G, the first temperature detection terminal NTC1, and the second temperature detection terminal NTC2 can each be provided with multiple pins. This improves current flow capability, enabling the power factor correction module 100 to connect more flexibly and communicate more quickly with external devices or systems. Furthermore, it enhances the heat dissipation capacity of each terminal, allowing the power factor correction module 100 to improve heat dissipation efficiency by increasing the contact area between the terminal and the external device during high-load operation, thereby avoiding performance degradation or damage due to overheating. In addition, the multiple-pin design can improve the electrical connection reliability of the module and reduce the risk of failure due to poor contact.

[0074] In one feasible implementation, refer to Figure 3 The power factor correction module 100 also includes a first temperature detection terminal NTC1, a second temperature detection terminal NTC2, and a temperature detection circuit 30. The temperature detection circuit 30 is formed on the substrate and is electrically connected to the first temperature detection terminal NTC1 and the second temperature detection terminal NTC2, respectively. The temperature detection circuit 30 is used to detect the temperature of the power factor correction module 100.

[0075] In this embodiment, the temperature detection circuit 30 may include a temperature sensor, such as a thermistor 301 or a thermocouple, to monitor the operating temperature of the power factor correction module 100 in real time. When the temperature exceeds a preset safety threshold, the temperature detection circuit 30 can trigger a protection mechanism, such as reducing power output or shutting down the module, to prevent damage caused by overheating. Furthermore, the output of the temperature detection circuit 30 can be fed back to the control system as one of the bases for adjusting the operating state of the power factor correction module 100, thereby achieving more precise temperature management. In this way, it can be ensured that the power factor correction module 100 maintains good performance and stability under various operating conditions.

[0076] In one feasible implementation, refer to Figure 4 The temperature detection circuit 30 includes a thermistor 301, the first end of which is connected to the first temperature detection terminal NTC1, and the second end of which is connected to the second temperature detection terminal NTC2.

[0077] In this embodiment, the resistance of the thermistor 301 changes with temperature. When the temperature of the power factor correction module 100 increases, the resistance of the thermistor 301 increases accordingly, resulting in a decrease in the current flowing through the thermistor 301. The temperature detection circuit 30 can be designed to detect this current change and convert it into a temperature signal. Based on the temperature signal, it can determine whether the module is overheating and take corresponding measures, such as adjusting the power output or activating the cooling system, to maintain the module operating within a safe temperature range. Thus, the temperature detection circuit 30 not only provides real-time temperature monitoring but also assists the control system in achieving intelligent management of the power factor correction module 100, ensuring its long-term stable operation.

[0078] In one feasible implementation, the temperature detection circuit 30 uses a thermistor 301, which detects the NTC detection temperature, and the switching transistor in the switching circuit 20 is an IGBT. (Reference) Figure 6 The diagram illustrates the relationship between NTC detection temperature and IGBT junction temperature (where the horizontal axis represents NTC detection temperature and the vertical axis represents IGBT junction temperature). This allows for the reading of the NTC temperature and its conversion to the IGBT junction temperature, determining whether the rated maximum junction temperature has been exceeded. When the IGBT junction temperature approaches its rated maximum, the switching frequency can be reduced to decrease the heat generated by the power factor correction module 100, or the IGBT can be shut down to prevent damage due to overheating. Furthermore, real-time monitoring of the IGBT junction temperature optimizes the efficiency of the power factor correction module 100, ensuring it operates within its optimal temperature range and extending its lifespan.

[0079] In one feasible implementation, refer to Figure 4The second AC input terminal AC2, the second DC output terminal DC-, the first temperature detection terminal NTC1, the second temperature detection terminal NTC2, the ground terminal GND, and the control signal access terminal G are arranged sequentially on the first side of the power factor correction module 100; the first AC input terminal AC1, the first DC output terminal DC+, the transformer input terminal PFC, and the high voltage access terminal P are arranged sequentially on the second side of the power factor correction module 100.

[0080] In this embodiment, since the first temperature detection terminal NTC1 and the second temperature detection terminal NTC2 are used to connect the thermistor 301, which is also a low-voltage terminal, setting the first temperature detection terminal NTC1 and the second temperature detection terminal NTC2 on the same side of the second DC output terminal DC-, the ground terminal GND and the control signal input terminal G of the power factor correction module 100 can reduce the electromagnetic interference of the high-voltage terminal to the first temperature detection terminal NTC1 and the second temperature detection terminal NTC2 and improve the accuracy of temperature detection. Furthermore, since the second AC input terminal AC2, the second DC output terminal DC-, the first temperature detection terminal NTC1, the second temperature detection terminal NTC2, the ground terminal GND, and the control signal input terminal G are arranged sequentially on the first side of the power factor correction module 100, that is, the first temperature detection terminal NTC1 and the second temperature detection terminal NTC2 are located in the middle of one side of the power factor correction module 100, the temperature detection circuit 30 can be easily set in the middle of the power factor correction module, thereby obtaining the overall temperature of the power factor correction module 100, avoiding misjudgment caused by uneven heating of the power factor correction module 100, and thus further enhancing the safety of the power factor correction module 100.

[0081] In this embodiment, the power factor correction module 100 includes a substrate, a rectifier circuit 10, a switching circuit 20, a DC output terminal (DC), a transformer input terminal (PFC), and a high-voltage access terminal (P). The rectifier circuit 10 and the switching circuit 20 are formed on the substrate. The DC output terminal (DC) is electrically connected to the rectifier circuit 10, the transformer input terminal (PFC) is electrically connected to the switching circuit 20, and the high-voltage access terminal (P) is connected to the output terminal of the switching circuit 20. The high-voltage access terminal (P) is used to connect to an external load RL. The DC output terminal (DC) and the transformer input terminal (PFC) are respectively used to connect to the two ends of an external inductor RL, so that when an external inductor 401 is connected, the external inductor 401 and the switching circuit 20 form a PFC loop to adjust the DC power output of the high-voltage access terminal (P), thereby adjusting the power factor of the external load. Since the switching circuit 20 and the rectifier circuit 10 are integrated on the same substrate, the number of components in the rectifier circuit 10 and the PFC circuit is reduced, the size of the rectifier circuit 10 and the PFC circuit is reduced, and the installation convenience of the rectifier circuit 10 and the FPC circuit is improved.

[0082] This application also proposes a controller, which includes an inductor 401 and a power factor correction module 100. The two ends of the inductor 401 are connected to a DC output terminal (DC) and a transformer input terminal (PFC), respectively. Specifically, this controller is a PFC controller, which connects to the DC output terminal (DC) and the transformer input terminal (PFC) of the power factor correction module 100 via the inductor 401, forming a closed-loop control system. By precisely controlling the current of the inductor 401, the controller can effectively adjust the output of the power factor correction module 100 to adapt to changes in the external load RL, ensuring that the power factor is always maintained at an optimal state. Since this controller adopts all the technical solutions of the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here.

[0083] In one feasible implementation, the number of power factor correction modules 100 is set to multiple, and the multiple power factor correction modules 100 are connected in parallel. (See reference) Figure 5 This embodiment describes a controller comprising three inductors 401 and three power factor correction modules 100. In practical applications, the number of power factor correction modules 100 can be adjusted, for example, to one, two, or four, etc., and is not limited here. Each power factor correction module 100 is equipped with a corresponding inductor 401. Each inductor 401 is connected between the DC output terminal (DC) and the transformer input terminal (PFC) of the corresponding power factor correction module 100. The first AC input terminal (AC1) and the second AC input terminal (AC2) of each power factor correction module 100 are connected to AC power. The first DC output terminal and the second DC output terminal of each power factor correction module 100 are connected to each other to achieve parallel operation of the three power factor correction modules 100. When multiple power factor correction modules 100 operate simultaneously, the rectifier circuit 10 and the switching circuit 20 of each power factor correction module 100 are integrated on the same substrate. The switching transistors of their respective switching circuits 20 are synchronously controlled by control signals (such as PWM signals) so that the input current waveform of each module is consistent with the input voltage waveform, thereby achieving high power factor correction of the external load.

[0084] In this embodiment, by setting the number of power factor correction modules 100 to multiple modules connected in parallel, higher power factor correction efficiency can be achieved. The multiple power factor correction modules 100 connected in parallel can share the load current, thereby reducing the workload of each module and extending its service life. Furthermore, redundancy is provided; if one power factor correction module 100 fails, the other power factor correction modules 100 can continue to operate, ensuring stable system operation.

[0085] In this embodiment, the number of inductors 401 and power factor correction modules 100 can be flexibly configured according to actual power requirements. For example, when the system needs to process a large amount of power, the number of inductors 401 and power factor correction modules 100 can be appropriately increased to meet higher power processing requirements. Conversely, if the system load is small, the corresponding number can be reduced to optimize cost and space utilization. Each additional set of inductors 401 and power factor correction modules 100 doubles the power requirement that set of inductors 401 and power factor correction modules 100 can meet. This allows for flexible adjustment of the number of inductors 401 and power factor correction modules 100 to achieve precise matching with system power requirements. In addition, it facilitates standardized production, enabling the design of a series of products with different power levels.

[0086] This application also proposes an electrical device, which includes a power factor correction module 100 and / or a controller. In this embodiment, the electrical device can be a household appliance such as an air conditioner, refrigerator, washing machine, television, or computer, or it can be large industrial equipment such as a motor drive system or automated production line. Since this controller adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.

[0087] The above are merely exemplary embodiments of this application and do not limit the patent scope of this application. Any equivalent structural transformations made based on the technical concept of this application and the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A power factor correction module, characterized in that, include: Substrate; A rectifier circuit is formed on the substrate; A switching circuit is formed on the substrate; A DC output terminal, which is electrically connected to the rectifier circuit; A transformer input terminal, which is electrically connected to the switching circuit; A high-voltage access terminal is connected to the output terminal of the switching circuit and is used to connect to an external load. The DC output terminal and the transformer input terminal are respectively used to connect to the two ends of an external inductor, so that when an external inductor is connected, the external inductor and the switching circuit form a PFC loop.

2. The power factor correction module as described in claim 1, characterized in that, The substrate has a first side surface, on which both the rectifier circuit and the switching circuit are formed.

3. The power factor correction module as described in claim 2, characterized in that, The power factor correction module also includes: A package housing is disposed on the substrate to encapsulate the rectifier circuit and the switching circuit within the package housing.

4. The power factor correction module as described in claim 3, characterized in that, The substrate also has a second side surface disposed opposite to the first side surface, the second side surface being exposed outside the packaging housing.

5. The power factor correction module as described in claim 1, characterized in that, The power factor correction module also includes: Multiple pins are connected to the DC output terminal, the transformer input terminal and the high voltage access terminal, respectively.

6. The power factor correction module as described in claim 5, characterized in that, The number of pins connected to the DC output terminal and / or the transformer input terminal and / or the high voltage access terminal is multiple, and the multiple pins are arranged in parallel.

7. The power factor correction module as described in claim 4, characterized in that, The DC output terminal includes: a first DC output terminal and a second DC output terminal, wherein the first DC output terminal and the second DC output terminal are used to output DC power formed by rectifying AC power through the rectifier circuit; The power factor correction module also includes: The first AC input terminal and the second AC input terminal are electrically connected to the rectifier circuit, respectively. The first AC input terminal and the second AC input terminal are used to receive AC power so as to output AC power to the rectifier circuit. A grounding terminal is electrically connected to the switching circuit to ground the switching circuit. A control signal input terminal is electrically connected to the switching circuit and is used to input control signals to control the conduction state of the switching circuit; The second DC output terminal, the grounding terminal, and the control signal access terminal are arranged sequentially on the first side of the power factor correction module; the first AC input terminal, the first DC output terminal, the transformer input terminal, and the high voltage access terminal are arranged sequentially on the second side of the power factor correction module.

8. The power factor correction module as described in claim 5, characterized in that, The second AC input terminal is located on the first side and on the side of the second DC output terminal away from the ground terminal.

9. The power factor correction module as described in claim 5, characterized in that, The distance between the second AC input terminal and the second DC output terminal is greater than the distance between the second DC output terminal and the ground terminal, and the distance between the second AC input terminal and the second DC output terminal is greater than the distance between the ground terminal and the control signal access terminal.

10. The power factor correction module as described in any one of claims 1 to 9, characterized in that, The power factor correction module also includes: First temperature detection terminal; Second temperature detection terminal; A temperature detection circuit is formed on the substrate; the temperature detection circuit is electrically connected to the first temperature detection terminal and the second temperature detection terminal respectively; the temperature detection circuit is used to detect the temperature of the power factor correction module.

11. A controller, characterized in that, The controller includes an inductor and a power factor correction module as described in any one of claims 1 to 10, wherein the two ends of the inductor are respectively connected to the DC output terminal and the transformer input terminal.

12. The controller as claimed in claim 11, characterized in that, The power factor correction module is a plurality of modules, and the plurality of power factor correction modules are connected in parallel.

13. An electrical appliance, characterized in that, The electrical device includes a power factor correction module as described in any one of claims 1 to 10, and / or includes a controller as described in claim 11 or 12.

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