7-Switch Flying Capacitor Converter for PoL Efficiency

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Solution Overview

Problem

Custom buck converters used in point-of-load (PoL) DC-DC converters increase system-level design complexity and manufacturing costs while affecting reliability due to the need for dedicated designs for various voltage and power levels, and they fail to provide a flexible solution for a wide range of voltages and power levels with high efficiency.

Innovation Solution

A 7-switch flying capacitor converter device that operates in multiple modes based on operating conditions, utilizing seven switches and a digital controller with mode selection logic to choose the most efficient operation mode, reducing unnecessary losses and enabling a wide range of voltage and power processing capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If custom buck converters are used for each functional block, then efficiency and volume are optimized for each converter, but system-level design complexity and manufacturing costs increase

Engineering Contradiction:

Improveconverter efficiencyVSAvoidsystem-level design complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent implements a universal converter device that can function as multiple different buck converter configurations (single-phase, two-phase interleaved, three-phase interleaved) by using a set of seven switches that can be arranged in different patterns. This single multi-functional device replaces the need for multiple custom-designed converters, thereby reducing system-level design complexity and manufacturing costs while maintaining high efficiency for each operational mode.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Power

If custom buck converters are designed for each voltage and power level, then converter efficiency is maximized, but manufacturing costs and design complexity increase

Engineering Contradiction:

Improvepower levelsVSAvoidmanufacturing costs

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The converter device provides a universal solution that can deliver multiple power levels and voltage conversions through different switching configurations. By using the same seven-switch architecture for all power levels, the patent eliminates the need for multiple custom designs, thereby reducing manufacturing costs while maintaining the ability to provide different power levels efficiently.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent achieves different power levels and voltage conversions by changing the switching parameters and duty cycles of the seven switches rather than changing the physical converter design. This allows a single converter to adapt to different power requirements, reducing manufacturing complexity and costs.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If multiple dedicated converters are used for different voltage levels, then each converter can be optimized, but the number of components and system complexity increase

Engineering Contradiction:

Improveconverter reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple converter functions into a single integrated device with seven switches that can be configured in different patterns. This consolidation reduces the total number of components compared to using multiple separate converters, while maintaining reliability through optimized switching configurations for each operational mode.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If a fixed converter design is used, then manufacturing is simplified, but flexibility to provide wide range of voltages and power levels is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidvoltage and power level range

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent achieves manufacturing simplicity by using a fixed seven-switch architecture that can be manufactured once and reused for all applications. The versatility to provide wide range of voltages and power levels is achieved through software-controlled switching configurations rather than hardware variations, allowing a single design to serve multiple purposes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The converter uses dynamic switching configurations where the seven switches can be arranged in different patterns based on the required output. This dynamic reconfiguration allows a single fixed hardware design to adapt to different voltage and power level requirements, maintaining manufacturing simplicity while achieving high versatility.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10720836B2Converter device and method to operate said converter device

Publication Date: 2020.07.21 WURTH ELEKTRONIK EISOS

AI summary

A converter device includes a converter and a controller to operate the converter. The converter includes reactive components which include a flying capacitor. To perform at least two different operation modes, the converter further includes seven switches. A mode selection logic of the controller selects one of the operation modes depending on desired operating conditions. The converter device is highly flexible and enables a high power processing efficiency over the full operating range by properly selecting a suitable operation mode.