High-Voltage Capacitor Charger With Nested Bobbin Transformer
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Solution Overview
Problem
Conventional high-voltage power supplies for capacitive pulsed power systems face challenges in achieving high power density due to leakage inductance in transformers, leading to size and power restrictions, and require complex control schemes for bipolar charging without a center tap, resulting in potential premature discharges.
Innovation Solution
A compact, high-voltage power supply with a low leakage inductance transformer and bipolar rectifying multiplier, utilizing a nested bobbin assembly with Litz wire and nano-crystalline amorphous C-sections, and a quadrupling full-wave multiplier to reduce leakage inductance and achieve passively balanced bipolar output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a transformer with large turn ratio is used to step up output voltage for high-voltage supply, then high voltage is achieved, but leakage inductance increases leading to higher resonant frequency and reduced power density
Solution Approach 1:
The patent employs a nested bobbin structure where multiple bobbins are placed concentrically within each other. The primary winding is on an inner bobbin, and secondary windings are on outer bobbins that nest around it. This nested arrangement minimizes the mean turn length and reduces leakage inductance while achieving the required voltage transformation ratio, thereby increasing power density.
2Volume of moving object
If resonant frequency is increased to reduce magnetic component size, then compact supply is achieved, but leakage inductance must be reduced which complicates transformer design
Solution Approach 1:
The nested bobbin structure allows multiple windings to be arranged in a compact concentric configuration, reducing the overall volume of magnetic components while maintaining low leakage inductance. The nested arrangement optimizes the magnetic coupling between windings without requiring complex external structures.
Solution Approach 2:
The patent transitions from planar or linear winding arrangements to a three-dimensional nested bobbin configuration. By stacking bobbins concentrically along the magnetic core, the design utilizes the third dimension to achieve compact volume while optimizing electrical parameters through controlled winding geometry.
3Adaptability or versatility
If two separate power supplies are used for bipolar charging without center tap, then bipolar output is achieved, but circuit parasitic elements cause voltage imbalance and premature discharges
Solution Approach 1:
The patent combines two separate bipolar power supply circuits into a single integrated circuit that generates both positive and negative output voltages. This unified design uses a single oscillating field and shared magnetic core, eliminating the need for separate supplies and their associated ground return paths, thereby preventing voltage imbalance caused by parasitic elements.
Solution Approach 2:
The patent creates a symmetric bipolar output by using a single oscillating field that induces equal and opposite voltages in two secondary windings. This copying approach ensures that both polarities are generated from the same source, guaranteeing voltage balance and eliminating the need for complex control schemes to maintain symmetry.
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 solution enables a compact, high-power-density capacitor charger with a single circuit driving both polarities, reducing size and complexity, achieving over 10× power density increase and automatic charge balance, allowing high-voltage charging with low leakage inductance and efficient energy transfer.
Implementation Method 1
a transformer with a large turn ratio is required to step up the output voltage
Implementation Method 2
Litz wire
Implementation Method 3
resonant supplies are often designed with a resonant frequency near equal to the switching frequency
Data Source
AI summary
An exemplary rectifying capacitor multiplier is provided for high voltage. The multiplier includes first and second circuit boards, a series of diodes in pattern groups, first and second packs of capacitors, and a pair of high voltage terminals. The circuit boards are disposed mutually in parallel. The pattern groups are disposed between the first and second circuit boards, with the diodes concatenated in series. The packs are disposed respectively on the respective circuit boards. Each pack distributes a capacitor that connects to a corresponding pattern group. The terminals correspond to positive and negative output voltages and are disposed on opposite sides of the circuit boards.