Apparatus, power converter and system

Abstract

Embodiments of this application relate to devices, power converters, and systems using current multiplier rectifiers. According to one embodiment, the device may include a transformer and a current multiplier rectifier, the transformer including a primary winding and one or more secondary windings, the primary winding including a portion of a power supply circuit; the current multiplier rectifier is connected in parallel with one or more secondary windings of the transformer, and the output voltage may be provided by the current multiplier rectifier.

Description

Technical Field

[0001] This application generally relates to power converters, and more specifically, to a DC-DC power converter with a current multiplier rectifier. Summary of the Invention

[0002] Embodiments of this application relate to devices, power converters, and systems using current multiplier rectifiers. According to one embodiment, the device may include a transformer and a current multiplier rectifier; the transformer includes a primary winding and one or more secondary windings, wherein the primary winding may include a portion of a power supply circuit; the current multiplier rectifier is connected in parallel with one or more secondary windings of the transformer, wherein the output voltage may be provided by the current multiplier rectifier.

[0003] According to one aspect of the device, the current doubler rectifier may include a first output inductor and a second output inductor.

[0004] According to one aspect of the device, the first output inductor and the second output inductor may include independent inductors with independent magnetic cores.

[0005] According to one aspect of the device, the first output inductor and the second output inductor can be connected in series.

[0006] According to one aspect of the device, the first output inductor and the second output inductor may include coupled inductors having a common magnetic core.

[0007] According to one aspect of the device, the output voltage provided by the current multiplier rectifier can be provided between the first output inductor and the second output inductor.

[0008] According to another embodiment, the power converter may include a power supply circuit, a transformer including a primary winding and one or more secondary windings; wherein the primary winding includes a portion of the power supply circuit, and a current multiplier rectifier connected in parallel with one or more secondary windings of the transformer; wherein the output voltage of the power converter may be provided by the current multiplier rectifier.

[0009] According to one aspect of the power converter, the current doubler rectifier may include a first output inductor and a second output inductor.

[0010] According to one aspect of the power converter, the first output inductor and the second output inductor may include independent inductors with independent magnetic cores.

[0011] According to one aspect of the power converter, the first output inductor and the second output inductor can be connected in series.

[0012] According to one aspect of the power converter, the first output inductor and the second output inductor may include coupled inductors having a common magnetic core.

[0013] According to one aspect of the power converter, the output voltage provided by the current doubler rectifier can be provided between the first output inductor and the second output inductor.

[0014] According to another embodiment, the system may include a DC-DC power converter that provides and outputs voltage to at least a portion of the system. The DC-DC power converter may include a power supply circuit, a transformer including a primary winding and one or more secondary windings; wherein the primary winding includes a portion of the power supply circuit and a current doubler rectifier connected in parallel with one or more secondary windings of the transformer; wherein the output voltage of the DC-DC power converter may be provided by the current doubler rectifier.

[0015] According to one aspect of the system, the current doubler rectifier may include a first output inductor and a second output inductor.

[0016] According to one aspect of the system, the first output inductor and the second output inductor may include independent inductors with independent magnetic cores.

[0017] According to one aspect of the system, the first output inductor and the second output inductor can be connected in series.

[0018] According to one aspect of the system, the first output inductor and the second output inductor may include coupled inductors having a common magnetic core. Attached Figure Description

[0019] Figure 1 This is a block diagram illustrating a schematic configuration of a conventional isolated DC-DC power converter;

[0020] Figure 2 This is a circuit diagram illustrating a schematic configuration of a non-isolated DC-DC power converter with interconnected transformer windings;

[0021] Figure 3 This is a circuit diagram illustrating a schematic configuration of a DC-DC power converter with a current multiplier rectifier according to an embodiment of this application;

[0022] Figure 4 This is a circuit diagram illustrating a schematic configuration of a DC-DC power converter with a current multiplier rectifier according to another embodiment of this application;

[0023] Figure 5 This is a schematic diagram illustrating an exemplary coupled inductor according to an embodiment of this application.

[0024] In the accompanying drawings, similar parts and / or features may have the same reference numerals. Furthermore, various parts of the same type can be distinguished by adding letters after the reference numerals to differentiate them. If only the first reference numeral is used in the description, the description applies to any similar part having the same first reference numeral, regardless of how the second reference numerals are used. Detailed Implementation

[0025] The accompanying drawings illustrate this application, wherein the same reference numerals are used to refer to the same elements throughout. In the following description, numerous specific details are set forth for ease of explanation in order to provide a full understanding of the innovation of this application. However, it will be apparent that this application can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form to facilitate the description of the innovation of this application.

[0026] Furthermore, the term “exemplary” as used herein means used as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as superior to or better than other aspects or designs. Rather, the use of the term “exemplary” is intended to present concepts in a concrete manner. As used herein, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless otherwise stated or clearly apparent from the context, “X adopts A or B” is intended to mean any natural inclusive arrangement. That is, if X adopts A; X adopts B; or X adopts both A and B, then “X adopts A or B” is satisfied in any of the foregoing cases. Furthermore, unless otherwise stated or clearly apparent from the context to refer to the singular form, the articles “a” and “an” used herein and in the appended claims should generally be construed as meaning “one or more.” Additionally, the word “coupled” as used herein means direct or indirect electrical or mechanical coupling.

[0027] An embodiment of this application described herein relates to a DC-DC power converter. This DC-DC power converter can be used to deliver power from a source having a high DC voltage to a low DC voltage. The term "converter" as used herein includes, but is not limited to, any or a combination of "regulator," "DC regulator," "voltage regulator," "DC voltage regulator," "DC-DC converter," "DC converter," and "converter," and includes, but is not limited to, the literal meaning of any of these terms.

[0028] Figure 1This is a block diagram illustrating a schematic configuration of a conventional isolated DC-DC power converter 100. An isolated power converter isolates the input from the output by electrically and physically separating the power converter's circuitry into two parts, thereby preventing the flow of DC current between the input and output. This is typically achieved using a transformer. The power converter 100 typically includes a primary side 104, which includes one or more power circuit switching elements (not shown). The primary side 104 receives an input voltage from a voltage source Vin. The power converter 100 also includes a secondary side 108, which may include, for example, rectifier circuitry, filter circuitry, and a load (not shown). The secondary side 108 outputs an output voltage Vout. The secondary side 108 is isolated from the primary side via, for example, a transformer 112 having one or more primary windings and one or more secondary windings. The power converter 100 also includes control circuitry 116, which controls the power converter 100 by determining when one or more power circuit switching elements are turned on and off. The control circuit 116 typically senses the voltage and current at the input, the voltage and current at the output, and / or the voltage and current within the power converter 100. In this conventional isolated DC-DC power converter 100 topology, since both the primary side 104 and the secondary side 108 have their own loops or ground references, the current flowing in the primary side 104 circulates only in the primary side 104, and the current flowing in the secondary side 108 circulates only in the secondary side 108.

[0029] In traditional topologies, transformers are typically required to achieve high voltage conversion from input to output for optimal efficiency. However, due to the large number of turns in the primary winding and the high AC component in the secondary winding, using transformers results in significant winding losses, thereby increasing the cost of the windings and printed circuit boards.

[0030] Figure 2This is a circuit diagram illustrating a schematic configuration of a non-isolated DC-DC power converter with interconnected transformer windings. More specifically, this example illustrates a DC-DC power converter such as U.S. Patent Application No. 17 / 477,734, filed by Appelberg on September 17, 2021, entitled "Non-isolated Pulse Width Modulation (PWM) Full-Bridge Power Converter with Interconnected Windings," now published as U.S. Patent No. 11,967,905, the entire contents of which are incorporated herein by reference for all purposes. As described herein, the power converter 200 includes a power supply circuit 204, which includes a plurality of power supply circuit switching elements. The plurality of power supply circuit switching elements includes two power supply circuit switching elements connected in parallel with two power supply circuit switching elements connected in series; X1, X2, X4, and X5 are arranged in a full-bridge configuration. The power supply circuit switching elements X1, X2, X4, and X5 may include, for example, metal-oxide-semiconductor field-effect transistors (MOSFETs) or gallium nitride (GaN) field-effect transistors (FETs). The power supply circuit 204 also includes an input voltage source 208 for providing a DC input voltage Vin to the power supply circuit switching elements X1, X2, X4, and X5. The power supply circuit 204 is configured to generate a unipolar square wave voltage.

[0031] The power converter 200 also includes an output voltage 212 for providing the converted DC voltage as the output voltage Vout, a transformer TX, a rectifier circuit 220, a filter circuit 224, and a load 228.

[0032] An input capacitor Cin is coupled in parallel between the input voltage source 208 and the power supply circuit switching elements X1, X2, X4, X5. The input capacitor Cin acts as a filter for the input voltage Vin and buffers energy. The transformer TX includes a primary winding Np coupled to the power supply circuit switching elements X1, X2, X4, X5, secondary windings Ns1, Ns2 coupled to the rectifier circuit 220, and an output inductor 236Lout. The number of windings associated with each of the primary winding Np and secondary windings Ns1, Ns2 can be any suitable value and varies depending on the embodiment. The filter circuit 224 includes a capacitor Cout, and the load 228 is represented by a resistor R mounted in parallel with the filter circuit 224. The capacitor Cout is used to smooth the rectified voltage reaching the load 228. The filter circuit 224 is mounted in parallel with the rectifier circuit 220.

[0033] like Figure 2As shown, the rectifier circuit 220 includes two power circuit switching elements, which include parallel diodes X3 and X6 for providing synchronous rectification. In some embodiments, the rectifier circuit 220 may include more or fewer switching devices and / or be configured to not have synchronous rectification, if desired.

[0034] Further, in this example embodiment, the drain node (D) of power circuit switching element X1 and the drain node (D) of power circuit switching element X4 are connected to the input voltage source Vin. Further, the source node (S) of power circuit switching element X1 is coupled to the drain node (D) of power circuit switching element X2 (switching node SW1). The source node (S) of power circuit switching element X4 is coupled to the drain node (D) of power circuit switching element X5 (switching node SW2). The source node (S) of power circuit switching element X2 is coupled to switching node SW2. The source node (S) of power circuit switching element X5 is coupled to switching node SW4. The drain (D) of power circuit switching element X3 is connected to switching node SW2; the source (S) of power circuit switching element X3 is grounded. The drain (D) of power circuit switching element X6 is connected to node SW4; the source (S) of power circuit switching element X6 is grounded.

[0035] Figure 2 The power converter 200 includes one or more controllers 250 for generating control signals, such as pulse-width modulated (PWM) signals, for the power circuit switching elements X1, X2, X3, X4, X5, X6. Figure 2 As shown, control signal A controls power circuit switching elements X1 and X5; control signal B controls power circuit switching elements X2 and X4; control signal A_Inverse controls power circuit switching element X6; and control signal B_Inverse controls power circuit switching element X3. According to an alternative embodiment of this application, for control reasons (e.g., compensating for delays in the drive circuit, different modulations during startup, etc.), control signal A can be split into two control signals (A_X1 and A_X5), and control signal B can be split into two control signals (B_X2 and B_X4). Figure 2 The controller 250 may include one or more gate drive circuits and / or other suitable drive circuits to generate control signals.

[0036] The controller 250 is adapted to change the duty cycle of control signals (e.g., A, B, A_Inverse, B_Inverse) to regulate the output voltage Vout. Normally, the frequency is kept constant, but it can be modulated to reduce current ripple. Figure 2As shown, the switching elements X1, X2, X4, and X5 in the power supply circuit are shunt or clamped by their inherent capacitance and their inherent body diodes. Figure 2 As shown, the power supply circuit switching elements X3 and X6 are shunt or clamped by their inherent output capacitors and their inherent body diodes.

[0037] In a non-isolated embodiment, a common ground (e.g., GND) is provided for the entire circuitry of the power converter 200. Therefore, the secondary windings Ns1 and Ns2 become part of the primary winding Np (e.g., interconnected with the primary winding Np). This arrangement provides several advantages. According to embodiments of this application, voltage regulation and the elimination of the capacitor divider section are achieved. According to embodiments of this application, during the charging phase, the primary winding Np is connected in series with the two ends of the secondary windings Ns1 and Ns2, depending on which phase of the power converter 200 is active.

[0038] Figure 3 This is a circuit diagram illustrating a schematic configuration of a DC-DC power converter with a current doubler rectifier according to an embodiment of this application. The example is shown as referenced above. Figure 2 The power converter 200 is described above. However, in this example, the transformer 305 (i.e., (Tx) as described above) is coupled to the current doubler rectifier 310. More specifically, the output voltage is provided by the current doubler rectifier 310, rather than by the output inductor 236 electrically coupled to the secondary windings (NS1 and Ns2) of the transformer as described above, and the output voltage 212 is provided by the output inductor 236.

[0039] In other words, the power converter 200 may include the power supply circuit 204 and transformer 305 as described above. Also as described above, the transformer 305 may include a primary winding (Np) and one or more secondary windings (Ns1 and Ns2); wherein the primary winding (Np) is a portion of the power supply circuit 204. A current-doubler rectifier 310 may be connected in parallel with one or more secondary windings (Ns1 and Ns2) of the transformer 305. The output voltage 212 of the power converter may be provided by the current-doubler rectifier 310.

[0040] The current doubler rectifier 310 may include a first output inductor (Lo1) and a second output inductor (Lo2). For example, as Figure 3 As shown, the first output inductor (Lo1) and the second output inductor (Lo2) may be independent inductors with independent magnetic cores. In this case, the first output inductor (Lo1) and the second output inductor (Lo2) may be connected in series. The output voltage 212 provided by the current doubler rectifier 310 may be provided or obtained at a point between the first output inductor (Lo1) and the second output inductor (Lo2).

[0041] Figure 4This is a circuit diagram illustrating a schematic configuration of a DC-DC power converter with a current doubler rectifier according to another embodiment of this application. Figure 3 Similar to the example shown above, this example also illustrates a power converter 200, wherein a transformer 305 is coupled to a current-doubler rectifier 310. As described above, the transformer 305 may include a primary winding (Np) and one or more secondary windings (Ns1 and Ns2), wherein the primary winding (Np) includes a portion of the power supply circuit 204. The current-doubler rectifier 310 may be connected in parallel with one or more secondary windings (Ns1 and Ns2) of the transformer 305. The output voltage 212 of the power converter may be provided by the current-doubler rectifier 310.

[0042] As in the previous example, the current doubler rectifier 310 may include a first output inductor (Lo1) and a second output inductor (Lo2). For example, as Figure 3 As shown, the first output inductor (Lo1) and the second output inductor (Lo2) can each be an independent inductor with an independent magnetic core. In this case, the first output inductor (Lo1) and the second output inductor (Lo2) can be connected in series. However, as... Figure 4 As shown in the example, the first output inductor (Lo1) and the second output inductor (Lo2) may include coupled inductors with a common magnetic core. Again, the output voltage 212 provided by the current doubler rectifier 310 may be provided or obtained at a point between the first output inductor (Lo1) and the second output inductor (Lo2).

[0043] Figure 5 This is a schematic diagram illustrating an exemplary coupled inductor according to an embodiment of this application. More specifically, this example shows another view of the common core 505 of the first output inductor (Lo1) and the second output inductor (Lo2) of the current doubler rectifier 310, as referenced above. Figure 4 The inductance currents 510 and 515 induced by the first output inductor (Lo1) and the second output inductor (Lo2), respectively, are also shown here. By coupling the first output inductor (Lo1) and the second output inductor (Lo2) together with a magnetic core 505, core losses can be reduced by magnetic flux offsetting.

[0044] Regardless of whether the first output inductor (Lo1) and the second output inductor (Lo2) are independent inductors with independent magnetic cores (such as...), Figure 3As shown, it is still implemented as an inductor sharing a common magnetic core. Compared to previous power converters, the embodiment described herein provides a smaller RMS current (Root Mean Square current) in the windings of transformer 305 of power converter 200. Compared to previous power converters, the embodiment also provides lower current stress in the output inductor, better load transients, lower ferromagnetic core losses due to output inductor coupling, and higher power conversion efficiency.

[0045] Exemplary apparatuses, systems, and methods have been described for power converters in this application. However, to avoid unnecessarily obscuring this application, many known structures and apparatuses have been omitted from the foregoing description. Such omissions should not be construed as limiting the scope of the claimed disclosure. Specific details are set forth to aid in understanding this application. However, it should be understood that this application can be implemented in a variety of ways beyond the specific details set forth herein.

[0046] The phrases “at least one,” “one or more,” “or,” and “and / or” are open-ended expressions that function as both conjunctions and participles. For example, each of the expressions “at least one of A, B, and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and / or C” indicates A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0047] The term "a" or "an" refers to one or more of the entities. Therefore, the terms "a" (or "an"), "one or more," and "at least one" are used interchangeably herein. It should also be noted that the terms "comprising," "including," and "having" are used interchangeably.

[0048] As used herein, the term "automatic" and its variations refer to any process or operation, typically continuous or semi-continuous, that can be performed without substantial human input. However, a process or operation can be automatic if input is received before its execution, even if the execution of the process or operation uses substantial or non-substantial human input. Human input is considered substantial if it influences how a process or operation is performed. Human input consenting to the execution of a process or operation is not considered "substantial."

[0049] The terms “determine,” “calculate,” “compute,” and their variations used herein are used interchangeably and include any type of method, process, mathematical operation, or technique.

[0050] This application includes, in various aspects, embodiments, and / or configurations, components, methods, processes, systems, and / or apparatuses substantially as shown and described herein, including aspects, embodiments, configuration embodiments, sub-combinations, and / or subsets. Those skilled in the art, upon understanding this application, will understand how to make and use the disclosed aspects, embodiments, and / or configurations. This application includes providing devices and processes in the absence of items not depicted and / or described herein, or in various aspects, embodiments, and / or configurations herein, where items might be used in prior equipment or processes, for example, to improve performance, achieve ease of use, and / or reduce implementation costs.

[0051] The foregoing discussion is for illustrative and descriptive purposes. It is not intended to limit this application to the form disclosed herein. For example, in the foregoing detailed description, various features of this application are combined in one or more aspects, embodiments, and / or configurations to simplify the application. Features of aspects, embodiments, and / or configurations of this application may be combined in alternative aspects, embodiments, and / or configurations other than those described above. This approach to disclosure should not be construed as reflecting an intention that the claims require more features than expressly recited in each claim. Rather, as reflected in the following claims, the inventive aspect lies in all features less than a single foregoingly disclosed aspect, embodiment, and / or configuration. Therefore, the following claims are hereby incorporated into this detailed description, each claim being an independent preferred embodiment of the application.

[0052] Furthermore, although this specification includes descriptions of one or more aspects, embodiments, and / or configurations, as well as certain variations and modifications, other variations, combinations, and modifications also fall within the scope of this disclosure, for example, which may fall within the skill and knowledge of someone skilled in the art after understanding this disclosure. It is intended to obtain the right to include alternative aspects, embodiments, and / or configurations to the permissible extent, including structures, functions, scopes, or steps that are substituted, interchangeable, and / or equivalent to the claimed structure, function, scope, or steps, whether such alternatives, interchangeable, and / or equivalent structures, functions, scopes, or steps are disclosed herein, and it is not intended to disclose any patentable subject matter.

Claims

1. An apparatus, characterized in that, include: A transformer, comprising a primary winding and one or more secondary windings; wherein the primary winding includes a portion of a power supply circuit. A current-doubler rectifier is connected in parallel with one or more of the secondary windings of the transformer; wherein the output voltage is provided by the current-doubler rectifier.

2. The apparatus according to claim 1, characterized in that, The current multiplier rectifier includes a first output inductor and a second output inductor.

3. The apparatus according to claim 2, characterized in that, The first output inductor and the second output inductor include independent inductors with independent magnetic cores.

4. The apparatus according to claim 3, characterized in that, The first output inductor and the second output inductor are connected in series.

5. The apparatus according to claim 2, characterized in that, The first output inductor and the second output inductor include coupled inductors having a common magnetic core.

6. The apparatus according to claim 2, characterized in that, The output voltage provided by the current doubler rectifier is provided between the first output inductor and the second output inductor.

7. A power converter, characterized in that, include: Power supply circuit; A transformer, comprising a primary winding and one or more secondary windings; wherein the primary winding includes a portion of a power supply circuit. A current-doubler rectifier is connected in parallel with one or more of the secondary windings of the transformer; wherein the output voltage of the power converter is provided by the current-doubler rectifier.

8. The power converter according to claim 7, characterized in that, The current multiplier rectifier includes a first output inductor and a second output inductor.

9. The power converter according to claim 8, characterized in that, The first output inductor and the second output inductor include independent inductors with independent magnetic cores.

10. The power converter according to claim 9, characterized in that, The first output inductor and the second output inductor are connected in series.

11. The power converter according to claim 8, characterized in that, The first output inductor and the second output inductor include coupled inductors having a common magnetic core.

12. The power converter according to claim 8, characterized in that, The output voltage provided by the current doubler rectifier is provided between the first output inductor and the second output inductor.

13. A system, characterized in that, include: A DC-DC power converter that provides an output voltage to at least a portion of the system; The DC-DC power converter includes: Power supply circuit; A transformer, comprising a primary winding and one or more secondary windings; wherein the primary winding includes a portion of a power supply circuit. A current-doubler rectifier is connected in parallel with one or more of the secondary windings of the transformer; wherein the output voltage of the DC-DC power converter is provided by the current-doubler rectifier.

14. The system according to claim 13, characterized in that, The current multiplier rectifier includes a first output inductor and a second output inductor.

15. The system according to claim 14, characterized in that, The first output inductor and the second output inductor include independent inductors with independent magnetic cores.

16. The system according to claim 15, characterized in that, The first output inductor and the second output inductor are connected in series.

17. The system according to claim 14, characterized in that, The first output inductor and the second output inductor include coupled inductors having a common magnetic core.

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