Alternating Switching Unit Layout for Fewer Capacitors in Power Modules
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Solution Overview
Problem
Conventional high-power power converter modules face limitations in conversion efficiency and size reduction due to the upper limit on the number of phase-staggered control signals, which restricts the phase number of parallel connections in power converter units.
Innovation Solution
The power converter module incorporates multiple switching circuit combinations with alternately arranged switching circuits and capacitors disposed between them. Control signals for different switching circuit combinations are partially out of phase, allowing AC currents through the same capacitor to be partially cancelled, thereby reducing the number of capacitors required while maintaining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If N-phase power converter units are connected in parallel with phase-staggered control signals to meet high-power output demand, then the current ripple of input and output is reduced and the required number of input and output capacitors is reduced, but the number of phase-staggered control signals reaches the upper limit and the phase number of parallel connections is limited
Solution Approach 1:
The power converter module is divided into multiple independent switching circuit combinations, each capable of operating autonomously. This segmentation allows the system to scale power output by adding more combinations without proportionally increasing control signal complexity, as each combination can be controlled independently or in coordinated groups.
Solution Approach 2:
The patent transitions from traditional single-plane parallel connection to a three-dimensional alternating arrangement where switching circuits from different combinations are interleaved in space. This spatial dimensionality change enables more efficient use of control signals and allows higher phase numbers without proportionally increasing control complexity.
2Reliability
If more capacitors are added to handle high-power output, then the power conversion reliability is improved, but the size of the power converter module increases
Solution Approach 1:
The patent applies partial phase-staggered control where not all switching circuits within a combination are fully phase-staggered, but rather a selective subset is used. This partial action reduces the required capacitance while maintaining sufficient reliability for high-power operation, thereby reducing module size without sacrificing power conversion reliability.
Solution Approach 2:
Multiple switching circuit combinations share common input and output capacitors through the alternating arrangement. This merging allows capacitors to serve multiple functions and support multiple switching circuits simultaneously, reducing the total number and size of capacitors needed while maintaining system reliability.
3Quantity of substance
If phase-staggered parallel connections are used to reduce current ripple, then the required number of capacitors is reduced, but the number of control signals reaches the upper limit
Solution Approach 1:
Switching circuits are grouped into multiple independent combinations, each with its own control signals. This segmentation allows the system to achieve ripple reduction through alternating arrangement without requiring a single complex phase-staggered control scheme for all circuits, thus avoiding the control signal upper limit while reducing capacitor requirements.
Solution Approach 2:
The alternating arrangement of switching circuits from different combinations creates a spatial interleaving pattern that enables capacitor sharing and ripple reduction without requiring extensive phase-staggered control signals. The spatial dimension replaces part of the control signal complexity with physical arrangement.
Data Source
AI summary
A power converter module includes a multilayer printed circuit board, a switching device, a controlling device and a capacitor device. The switching device includes two switching circuit combinations. Each of the switching circuit combinations includes two switching circuits connected in parallel. Each of the switching circuits includes a switching unit. The controlling device is configured for outputting a first control signal and a second control signal to control the switching circuits of the first switching circuit combination and the switching circuits of the second switching circuit combination respectively. The first control signal and the second control signal are out of phase with each other. On a direction, the switching units of the first switching circuit combinations and the switching units of the second switching circuit combinations are alternately arranged, each of a plurality of capacitors of the capacitor device is neighboring to the two adjacent switching units.