AC to DC Converter Switching Regulator Efficiency
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Solution Overview
Problem
Existing AC to DC converter technologies face inefficiencies and bulkiness, particularly when converting high voltage AC mains to low voltage DC for small electronic devices, leading to heat dissipation and incompatibility with system-on-a-chip integration, with efficiencies typically ranging from 60 to 70% and requiring bulky components.
Innovation Solution
An AC to DC power conversion system utilizing an efficient electronic switch to disconnect the input of a series voltage regulator circuit from rectified AC mains, storing energy in a shunt energy storage element and supplying it to the load when the switch is open, with a comparator controlling the switch to reduce power dissipation and enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional transformer-based approach is used to convert AC mains to low voltage DC, then voltage regulation is achieved, but the size and weight of the magnetic structure becomes too large for miniature equipment
Solution Approach 1:
The patent extracts and eliminates the transformer component from the power conversion system by implementing direct rectification of AC mains voltage. The circuit directly converts high voltage AC to low voltage DC through rectifier diodes and voltage regulation circuitry, removing the bulky magnetic structure entirely while maintaining voltage regulation functionality through solid-state components.
2Volume of stationary object
If direct rectification with shunt regulator is used to eliminate transformer, then size is reduced, but efficiency becomes very poor with excessive heat dissipation
Solution Approach 1:
The patent implements dynamic voltage regulation using a series-connected active solid-state device (transistor or MOSFET) that continuously adjusts its resistance to maintain stable output voltage. This dynamic control allows the regulator to operate efficiently across varying load conditions, significantly reducing power dissipation compared to static shunt regulator approaches while maintaining compact size.
Solution Approach 2:
The patent changes the operating parameters of the voltage regulation by using an active device in series configuration rather than shunt configuration. This parameter change enables the regulator to control output voltage by adjusting the series device's resistance, thereby minimizing current waste and improving efficiency from the poor efficiency of shunt regulators to high efficiency operation.
3Loss of energy
If series regulator is used to improve efficiency over shunt regulator, then power dissipation is reduced, but efficiency is still limited to the ratio of input to output voltage
Solution Approach 1:
The patent employs periodic switching action using a high-speed switching element that rapidly toggles between on and off states. This switching regulator architecture allows energy transfer in discrete packets, enabling the system to achieve efficiencies exceeding the traditional input-to-output voltage ratio limitation by recovering and transferring energy in controlled pulses rather than continuous linear regulation.
Solution Approach 2:
The patent ensures continuous energy transfer to the load through a combination of switching action and energy storage elements (inductors or capacitors). The switching regulator maintains continuous useful action by rapidly cycling energy storage components, ensuring uninterrupted power delivery to the load while minimizing energy loss during transfer, thereby achieving sustained high efficiency operation.
4Loss of energy
If switch mode power supply is used to achieve high efficiency, then power loss is reduced, but transformer losses and RF noise from high speed switching remain
Solution Approach 1:
The patent uses a simplified switching regulator architecture that copies the essential high-efficiency switching function without requiring a transformer. By implementing direct AC-to-DC conversion with switching action and energy storage elements, the system achieves high efficiency while eliminating transformer-related losses and reducing RF noise generation from the absence of high-speed magnetic switching.
5Power
If conventional AC to DC converter designs are used, then power conversion is achieved, but integration on chip with other system functions is not possible
Solution Approach 1:
The patent merges the AC-to-DC power conversion function with other system functions by implementing a highly integrated circuit design. The converter uses compact solid-state components including rectifier diodes, voltage regulation transistors, and energy storage elements that can be fabricated together on a single integrated circuit chip, enabling system-on-chip integration while maintaining full power conversion capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves high efficiency, reducing power dissipation and heat generation, enabling compact and integrated power converters suitable for low voltage electronic devices with efficiencies approaching 99 to 100%, suitable for integration in small devices and reducing the need for bulky external power supplies.
Implementation Method 1
An efficient electronic switch is employed to disconnect the input of a series voltage regulator circuit from a rectified AC mains power supply
Implementation Method 2
While the switch is closed, energy is accumulated and stored in a shunt energy storage element
Implementation Method 3
While the switch is open, energy is supplied to the load by the energy storage element through the regulator circuit
Implementation Method 4
A comparator is used to control the electronic switch
Data Source
AI summary
An improved AC to DC conversion system consists of an electronic switch employed to disconnect the input of a prior art series voltage regulator circuit from a rectified AC mains power supply over a fraction of the period of the AC mains to reduce the power dissipated within the series regulator.