A simple power factor correction integrated module

Abstract

The utility model discloses a simple and convenient power factor correction integrated module, including integrated module package, is used for realizing circuit integration package, the chip circuit that is packaged in the inside of integrated module package, this chip circuit includes rectifier bridge, is configured to be used for converting alternating current signal into direct current signal, the utility model realizes a simple and convenient peripheral, can output integrated power factor correction scheme of high low pressure, satisfies the requirement of energy consumption and mandatory standard. Simultaneously realizes low cost, low space occupancy, high -efficient heat management, has provided the cost -reducing space for home appliance scheme design. Due to the high degree of integration, low -voltage output is also integrated in the module inside, and the external design is very simple, only needs several capacitors, inductance, reduces and shortens the development difficulty and shortens development cycle. And because switching power supply loop design is in the module inside, reduces the loop interference of external design, and the control precision is guaranteed.

Description

Technical Field

[0001] This utility model belongs to the field of power factor correction technology, specifically relating to a simple integrated power factor correction module. Background Technology

[0002] Power factor correction (PFC) technology is a key technology for solving the problem of energy utilization efficiency in home appliances. In traditional home appliances, when devices with switching power supplies or motor drives draw current directly from the power grid, the nonlinear load characteristics cause severe distortion of the input current waveform, making it out of sync with the voltage waveform and generating a large amount of harmonic current. This manifests as a low power factor, resulting in low power grid transmission efficiency, increased line losses, and pollution of the power grid. With the implementation of global mandatory energy efficiency standards, power factor correction is increasingly becoming a standard feature in home appliance design.

[0003] Active PFC technology, by adding a dedicated control circuit between the rectifier bridge and the main capacitor, can force the input current waveform to follow the input voltage waveform, making it approximately sinusoidal and in phase. However, traditional active PFC circuits have many drawbacks: complex circuit design, requiring more external components; discrete components are scattered, occupying a large PCB space; consistency and compatibility issues exist when multiple components work together; significant inter-stage interconnection losses; both PFC and switching power supplies are high heat density sources, making thermal design difficult; the drive of the PFC circuit spans high-voltage and low-voltage areas, and unreasonable line and ground line design can easily introduce interference.

[0004] In existing technologies, traditional active software PFC circuits contain multiple discrete components, occupy a large PCB area, have bulky and redundant heat sinks, suffer from inter-stage interconnection losses, have numerous solder joints / connectors between discrete components, resulting in a high failure rate. Furthermore, they require multiple control chips and passive components, have high consistency requirements, and carry a high risk of defects. Additionally, a PFC intelligent module provided in publication number "CN115995954A" integrates a rectifier bridge, IGBT, driver chip, diodes, and sampling circuit within the module. However, the low-voltage power supply for the internal control chip still requires an externally designed step-down circuit, and improper grounding design can easily introduce interference affecting sampling. Utility Model Content

[0005] The purpose of this invention is to provide a simple integrated power factor correction module to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a simple integrated power factor correction module, comprising:

[0007] Integrated module package (IPC) is used to achieve integrated circuit packaging.

[0008] The chip circuit encapsulated within the integrated module package includes:

[0009] A rectifier bridge is configured to convert AC signals into DC signals.

[0010] Gate driver chip, configured to drive power switching transistors and integrates overcurrent protection function;

[0011] A current sampling chip is configured to sample the sampling resistor of the power factor correction circuit and output a pre-processed current signal.

[0012] A diode, together with a power switching transistor and an external inductor, forms a power factor correction boost circuit;

[0013] The power switching transistor, together with the diode and the external inductor, forms a power factor correction boost circuit;

[0014] A switching power supply chip configured to convert a high-voltage DC output with power factor correction into a low-voltage DC output;

[0015] Linear regulator chips are configured to convert the output voltage of a switching power supply into a more stable low voltage to power internal and external chips.

[0016] Preferably, the integrated module package has multiple external pins, including an input live wire terminal ACL, an input neutral wire terminal ACN, an external inductor 1 terminal L1, an external inductor 2 terminal L2, a PFC output terminal P, a ground terminal and an external sampling resistor 1 terminal G / Rs1, an external sampling resistor 2 terminal Rs2, a current sampling output terminal OP, a software PFC control terminal IN, a linear regulator output terminal LDO, a switching power supply feedback terminal fb, a switching power supply output terminal Vo, and a switching power supply node terminal Sw.

[0017] Preferably, the rectifier bridge is used to convert the input AC signal into a DC signal, and its input terminal is connected to the input live wire terminal ACL and the input neutral wire terminal ACN respectively.

[0018] Preferably, the gate driver chip is driven by the IN input signal of the software PFC control terminal to drive the power switching transistor, and the gate driver chip integrates overcurrent protection function.

[0019] Preferably, the current sampling chip is used to sample the external sampling resistor of the PFC circuit and output the current signal preprocessed by the operational amplifier through the current sampling output terminal OP.

[0020] Preferably, the diode is a fast recovery diode or a Schottky diode, and the power switch is an IGBT; the diode, the power switch, and the external inductor are connected through external inductor 1 and external inductor 2 to form a PFC boost circuit.

[0021] Preferably, the switching power supply chip is a BUCK-type switching power supply chip, which is used to convert the DC high voltage output by PFC into a low voltage. Its output terminal is connected to the output terminal Vo of the switching power supply, and the switching power supply chip receives feedback signals through the switching power supply feedback terminal fb to achieve output voltage stability.

[0022] Preferably, the input terminal of the linear regulator chip is connected to the output terminal of the switching power supply chip to convert the voltage output by the switching power supply into a more stable low voltage. Its output terminal is connected to the linear regulator output terminal LDO to supply power to the internal gate driver chip, current sampling chip and external chips.

[0023] Compared with the prior art, the technical effects and advantages of this utility model are as follows:

[0024] This invention provides a simple, integrated power factor correction scheme capable of outputting both high and low voltages, meeting energy consumption and mandatory standards. It also achieves low cost, low space occupation, and efficient thermal management, offering cost reduction opportunities for home appliance design. Due to its high degree of integration, with the low-voltage output also integrated within the module, external design is extremely simple, requiring only a few capacitors and inductors, significantly reducing development difficulty and time. Furthermore, because the switching power supply circuit is designed internally, external circuit interference is reduced, ensuring control accuracy. Attached Figure Description

[0025] Figure 1 This is a functional framework diagram of the power factor correction integrated module of this utility model;

[0026] Figure 2 This is a diagram of the integrated module package of this utility model;

[0027] Figure 3 This is an example diagram illustrating the application of the power factor correction integrated module of this utility model.

[0028] In the diagram: 101, integrated module package; 106, rectifier bridge; 107, gate driver chip; 108, current sampling chip; 109, diode; 110, power switch; 111, switching power supply chip; 112, linear regulator chip. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed", "equipped with", "sleeved with", "connected", etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0031] Please see Figure 1-3 This utility model provides a technical solution: a simple integrated power factor correction module, comprising:

[0032] The integrated module package 101 is used to realize circuit integrated packaging;

[0033] A chip circuit packaged inside an integrated module package 101, the chip circuit including:

[0034] Rectifier bridge 106 is configured to convert AC signals into DC signals;

[0035] Gate driver chip 107 is configured to drive power switching transistors and integrates overcurrent protection function;

[0036] The current sampling chip 108 is configured to sample the sampling resistor of the power factor correction circuit and output a pre-processed current signal.

[0037] Diode 109, together with the power switch and external inductor, forms a power factor correction boost circuit;

[0038] The power switch 110, together with the diode 109 and the external inductor, constitutes a power factor correction boost circuit;

[0039] The switching power supply chip 111 is configured to convert the high-voltage DC output of the power factor correction output into a low-voltage DC output.

[0040] The linear regulator chip 112 is configured to convert the output voltage of a switching power supply into a more stable low voltage to power internal and external chips.

[0041] The integrated module package 101 has multiple external pins, including input live wire terminal ACL, input neutral wire terminal ACN, external inductor 1 terminal L1, external inductor 2 terminal L2, PFC output terminal P, ground terminal and external sampling resistor 1 terminal G / Rs1, external sampling resistor 2 terminal Rs2, current sampling output terminal OP, software PFC control terminal IN, linear regulator output terminal LDO, switching power supply feedback terminal fb, switching power supply output terminal Vo, and switching power supply node terminal Sw.

[0042] The rectifier bridge 106 is used to convert the input AC signal into a DC signal, and its input terminal is connected to the input live wire terminal ACL and the input neutral wire terminal ACN respectively.

[0043] The gate driver chip 107 is driven by the IN input signal of the software PFC control terminal and is used to drive the power switch 110. The gate driver chip 107 also integrates overcurrent protection function.

[0044] The current sampling chip 108 is used to sample the external sampling resistor of the PFC circuit and output the pre-processed current signal through the current sampling output terminal OP.

[0045] Diode 109 is a fast recovery diode or a Schottky diode, and power switch 110 is an IGBT. Diode 109, power switch 110 and external inductor are connected through external inductor 1 and external inductor 2 to form a PFC boost circuit.

[0046] The switching power supply chip 111 is a BUCK type switching power supply chip, which is used to convert the DC high voltage output by PFC into low voltage. Its output terminal is connected to the output terminal Vo of the switching power supply, and the switching power supply chip 111 receives feedback signals through the switching power supply feedback terminal fb to achieve output voltage stability.

[0047] The input terminal of the linear regulator chip 112 is connected to the output terminal of the switching power supply chip 111 to convert the voltage output by the switching power supply into a more stable low voltage. Its output terminal is connected to the linear regulator output terminal LDO to supply power to the internal gate driver chip 107, the current sampling chip 108 and external chips.

[0048] This simple integrated power factor correction module is a highly integrated device designed to address the shortcomings of traditional discrete power factor correction (PFC) and switching power supply solutions in terms of space occupation, energy efficiency management, and cost control. Its specific structure and working logic are as follows:

[0049] The integrated module includes an integrated module package 101 and chip circuitry packaged inside it. Through the integrated package design, it realizes the core functions of power factor correction, simultaneous high and low voltage output, and simplification of peripheral circuitry.

[0050] Among them, the integrated module package 101 serves as the physical carrier of the entire module and is used to realize the integrated packaging of all internal chip circuits. Through processes such as molding and bonding, the internal circuit chips are fixed on the substrate to form a compact and easy-to-install integrated unit. Meanwhile, to enable connection to external circuits, the package has multiple external pins with clearly defined functions, including: Input live wire terminal ACL (for connecting to the mains live wire), Input neutral wire terminal ACN (for connecting to the mains neutral wire), External inductor 1 terminal L1 (connecting to one end of the external inductor), External inductor 2 terminal L2 (connecting to the other end of the external inductor), PFC output terminal P (outputting high-voltage DC after power factor correction), Ground terminal and external sampling resistor 1 terminal G / Rs1 (serving as the connection point between the module ground terminal and one end of the external sampling resistor), External sampling resistor 2 terminal Rs2 (connecting to the other end of the external sampling resistor), Current sampling output terminal OP (outputting the pre-processed current sampling signal), Software PFC control terminal IN (receiving external software control signals to drive the PFC circuit), Linear regulator output terminal LDO (outputting a stable low voltage after linear regulation), Switching power supply feedback terminal fb (receiving the feedback signal of the switching power supply output voltage), Switching power supply output terminal Vo (outputting the low voltage after switching power supply conversion), and Switching power supply node terminal Sw (the node lead-out terminal of the internal chopper circuit of the switching power supply).

[0051] The chip circuitry encapsulated within the integrated module package 101 is crucial for realizing the core functions. Its components and functions are as follows:

[0052] Rectifier bridge 106: As the front-end AC processing unit of the module, its core function is to convert the input AC signal into a DC signal. Specifically, the input terminal of rectifier bridge 106 is connected to the input live wire terminal ACL and the input neutral wire terminal ACN of integrated module package 101 through internal circuitry. When the AC power from the grid is input through ACL and ACN, rectifier bridge 106 uses the unidirectional conductivity of diodes to convert the alternating positive and negative AC power into unidirectional pulsating DC power, providing the basic DC input for the subsequent power factor correction circuit.

[0053] Gate driver chip 107 serves a dual purpose: driving the power switch transistor and ensuring circuit safety. It is configured to drive the power switch transistor 110. In operation, the control terminal of gate driver chip 107 is connected to the software PFC control terminal IN, receiving software control signals (such as PWM signals) from an external MCU or control circuit, and amplifying these signals to a level sufficient to drive the power switch transistor 110 on and off. Simultaneously, the chip integrates overcurrent protection; when an overcurrent condition is detected in the circuit, it quickly cuts off the drive signal to prevent damage to the power switch transistor 110 due to overcurrent, thus improving the module's safety and reliability.

[0054] Current sampling chip 108: As the sensing unit of the power factor correction circuit, it is configured to sample the sampling resistor of the power factor correction circuit and output a pre-processed current signal. It is connected to the ground terminal and the external sampling resistor 1 terminal G / Rs1 and the external sampling resistor 2 terminal Rs2 through internal circuitry. When the external sampling resistor is connected to the circuit, the current sampling chip 108 can detect the current flowing through the sampling resistor (this current reflects the operating current of the PFC circuit), and perform pre-processing such as amplification and filtering on the sampled signal through the internal operational amplifier circuit. Finally, the processed current signal is output to the external MCU through the current sampling output terminal OP, providing a basis for the MCU to realize closed-loop control of the PFC circuit (such as adjusting the conduction time of the power switch), ensuring that the input current waveform is synchronized with the voltage waveform, and improving the power factor.

[0055] Diode 109: As an important component of the power factor correction boost circuit, it works in conjunction with the power switch 110 and the external inductor to form the power factor correction boost circuit. Specifically, diode 109 is either a fast recovery diode or a Schottky diode (because both have short reverse recovery times and good high-frequency characteristics, suitable for the high-frequency switching operation of the PFC circuit). Its anode and cathode are connected to the power switch 110 and the PFC output terminal P respectively through internal circuitry. When the power switch 110 is turned off, it provides a path for the external inductor to release its stored energy, allowing the energy in the inductor to be transferred to the output terminal, thus increasing the voltage.

[0056] Power switch 110: Working in conjunction with diode 109 and external inductor, it forms the core switching unit of the power factor correction boost circuit. This power switch 110 is an IGBT (Insulated Gate Bipolar Transistor, combining the high-frequency characteristics of a MOSFET and the high-current characteristics of a GTR, suitable for high-voltage, high-current applications). Its gate is connected to the output terminal of the gate driver chip 107, and its drain and source are connected to the external inductor terminal L2 and ground respectively through internal circuitry. Driven by the gate driver chip 107, the power switch 110 periodically turns on and off: when on, the external inductor stores energy; when off, the external inductor releases energy, working with diode 109 to boost the voltage, ultimately providing a stable high-voltage DC current to the PFC output terminal P.

[0057] Switching power supply chip 111: As the core of the module's low-voltage conversion, it is configured to convert the high-voltage DC output from the power factor correction (PFC) circuit into a low-voltage circuit. Specifically, this chip uses a BUCK-type switching power supply chip (a step-down switching power supply topology characterized by high conversion efficiency). Its input terminal is connected to the PFC output terminal P via internal circuitry, receiving the PFC-corrected high-voltage DC. Through the on / off control of an internal high-frequency switching transistor, the high-voltage DC is chopped into high-frequency pulses. These pulses are then processed by internally integrated or externally matched filtering components such as inductors and capacitors, converting them into stable low-voltage DC (e.g., 12V, 15V). The output terminal of switching power supply chip 111 is connected to the switching power supply output terminal Vo, outputting the converted low-voltage voltage. Simultaneously, to ensure output voltage stability, the chip receives voltage feedback signals from the output terminal through the switching power supply feedback terminal fb, adjusting the duty cycle of the internal switching transistor in real time to maintain the output voltage at the set value.

[0058] Linear regulator chip 112: As a high-precision voltage regulator unit with low-voltage output, it is configured to convert the voltage output from the switching power supply into a more stable low voltage to power internal and external chips. Its input terminal is connected to the output terminal of the switching power supply chip 111 through internal circuitry, receiving the low voltage (e.g., 12V) output from the switching power supply. Through internal adjustment transistors and feedback circuits, this voltage is further regulated to a lower voltage (e.g., 5V, 3.3V, etc.) with higher precision and lower ripple. The output terminal of linear regulator chip 112 is connected to the linear regulator output terminal LDO. The stable low voltage output powers the control chips such as the gate driver chip 107 and the current sampling chip 108 inside the module, ensuring the stable operation of the internal circuitry. On the other hand, it can also power external low-voltage chips such as MCUs and sensors through the LDO terminal, reducing the need for additional external voltage regulator circuitry.

[0059] The working principle of this integrated module can be divided into two core processes: high-voltage output for power factor correction (PFC) and low-voltage conversion and power supply, as detailed below:

[0060] 1. Power Factor Correction (PFC) High Voltage Output Process

[0061] AC input and rectification

[0062] External high-voltage AC power is connected through the live wire (ACL) and neutral wire (ACN) input terminals of the integrated module package 101, and first enters the internal rectifier bridge 106. The rectifier bridge 106 converts the input AC signal into a DC signal, providing the basic DC input for the subsequent PFC boost circuit.

[0063] PFC boost circuit operation

[0064] The rectified DC signal enters the PFC boost circuit, which consists of diode 109, power switch 110 (IGBT), and an external inductor (connected via external inductor 1 terminal L1 and external inductor 2 terminal L2).

[0065] The gate driver chip 107 receives the control signal input from the PFC control terminal IN of the software and drives the power switch 110 to alternately turn on and off.

[0066] By combining the unidirectional conductivity of diode 109 with the energy storage / release function of external inductor, the rectified DC voltage is boosted, and finally the corrected high-voltage DC is output through PFC output terminal P (this output terminal is externally connected to a large bus capacitor to stabilize the voltage).

[0067] Current sampling and feedback

[0068] The current sampling chip 108 is connected to the external sampling resistor through the ground terminal and the external sampling resistor 1 terminal G / Rs1 and the external sampling resistor 2 terminal Rs2 to sample the current of the PFC circuit. After preprocessing by the operational amplifier, the current signal is output through the current sampling output terminal OP for external MCU analysis and closed-loop control to ensure the stable operation of the PFC circuit.

[0069] 2. Low-voltage conversion and power supply process

[0070] Switching power supply step-down

[0071] The high-voltage DC power output from the PFC is fed into the internal switching power supply chip 111 (BUCK type). The high-voltage DC power is stepped down to a low voltage (such as 12V, 15V, etc.) through high-frequency switching conversion and output through the switching power supply output terminal Vo. At the same time, the switching power supply chip 111 receives the feedback signal of the output voltage through the switching power supply feedback terminal fb and dynamically adjusts the conversion process to ensure the stability of the output low voltage.

[0072] Linear regulation and power supply

[0073] The low voltage output from the switching power supply is fed into the linear regulator chip 112, and after further voltage regulation, it is converted into a more stable low voltage. The voltage is then output through the linear regulator output terminal LDO to power the control chips such as the gate driver chip 107 and the current sampling chip 108 inside the module, and also to provide a stable power supply for external chips (such as MCU).

[0074] 3. By integrating the above circuits (rectification, PFC boost, sampling, switching power supply buck, linear regulation, etc.) into the package 101 and connecting to a small number of peripheral components (capacitors, inductors, etc.) through specific external pins, the module achieves simultaneous high and low voltage output. It also features simple peripheral design, small space occupation, low interstage loss, and strong anti-interference ability, making it suitable for scenarios such as home appliances with strict requirements for power factor and energy efficiency.

[0075] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A simple integrated power factor correction module, characterized in that, include: An integrated module package (101) is used to implement integrated circuit packaging; A chip circuit packaged inside an integrated module package (101), the chip circuit comprising: A rectifier bridge (106) is configured to convert AC signals into DC signals; A gate driver chip (107) is configured to drive power switching transistors and integrates overcurrent protection. A current sampling chip (108) is configured to sample the sampling resistor of the power factor correction circuit and output a preprocessed current signal; The diode (109), together with the power switch and the external inductor, forms a power factor correction boost circuit; The power switch (110), together with the diode (109) and the external inductor, constitutes a power factor correction boost circuit; A switching power supply chip (111) is configured to convert a high-voltage DC output with power factor correction into a low-voltage DC output. A linear regulator chip (112) is configured to convert the output voltage of a switching power supply into a more stable low voltage to power internal and external chips.

2. The simplified power factor correction integrated module according to claim 1, characterized in that: The integrated module package (101) has multiple external pins, including input live wire terminal ACL, input neutral wire terminal ACN, external inductor 1 terminal L1, external inductor 2 terminal L2, PFC output terminal P, ground terminal and external sampling resistor 1 terminal G / Rs1, external sampling resistor 2 terminal Rs2, current sampling output terminal OP, software PFC control terminal IN, linear regulator output terminal LDO, switching power supply feedback terminal fb, switching power supply output terminal Vo, and switching power supply node terminal Sw.

3. The simplified power factor correction integrated module according to claim 1, characterized in that: The rectifier bridge (106) is used to convert the input AC signal into a DC signal, and its input terminal is connected to the input live wire terminal ACL and the input neutral wire terminal ACN respectively.

4. The simplified power factor correction integrated module according to claim 1, characterized in that: The gate driver chip (107) is driven by the input signal of the software PFC control terminal IN and is used to drive the power switch (110). The gate driver chip (107) integrates overcurrent protection function.

5. A simplified power factor correction integrated module according to claim 1, characterized in that: The current sampling chip (108) is used to sample the external sampling resistor of the PFC circuit and output the current signal preprocessed by the operational amplifier through the current sampling output terminal OP.

6. A simplified power factor correction integrated module according to claim 1, characterized in that: The diode (109) is a fast recovery diode or a Schottky diode, and the power switch (110) is an IGBT. The diode (109), the power switch (110) and the external inductor are connected through the external inductor 1 terminal and the external inductor 2 terminal to form a PFC boost circuit.

7. A simplified power factor correction integrated module according to claim 1, characterized in that: The switching power supply chip (111) is a BUCK type switching power supply chip, which is used to convert the DC high voltage output by PFC into low voltage. Its output terminal is connected to the output terminal Vo of the switching power supply, and the switching power supply chip (111) receives feedback signals through the switching power supply feedback terminal fb to achieve output voltage stability.

8. A simple power factor correction integrated module according to claim 1, characterized in that: The input terminal of the linear regulator chip (112) is connected to the output terminal of the switching power supply chip (111) to convert the voltage output by the switching power supply into a more stable low voltage. Its output terminal is connected to the linear regulator output terminal LDO to supply power to the internal gate driver chip (107), the current sampling chip (108) and the external chip.

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