Coupled Inductor Buck Regulator for High Efficiency
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Solution Overview
Problem
Traditional non-isolated buck DC/DC converters are inefficient for converting high voltage supplies to low voltage outputs, such as from 12 volts to 1 volt, resulting in high conversion losses and low power efficiency due to small duty cycles.
Innovation Solution
A coupled inductor regulator system using conduction switches, freewheeling switches, and tightly coupled inductors with a coefficient of coupling greater than 0.99, operating at approximately 50% duty cycle, to efficiently convert input voltage to output voltage with minimal deadtime and reduced ripple current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional non-isolated buck DC/DC converters are used to convert 12V to 1V, then voltage conversion is achieved, but power efficiency deteriorates due to small duty cycle operation
Solution Approach 1:
The patent divides the single-stage buck converter into two separate buck converter stages. The first stage converts 12V to an intermediate voltage (e.g., 5V) with a moderate duty cycle, and the second stage converts the intermediate voltage to 1V also with a moderate duty cycle. This segmentation allows each stage to operate at higher efficiency compared to a single stage operating at extremely small duty cycle, thereby improving overall power efficiency and reducing conversion losses.
2Use of energy by moving object
If tightly coupled inductors with coefficient of coupling greater than 0.99 are used, then power efficiency is improved and DC current cancellation occurs, but device complexity increases
Solution Approach 1:
The patent merges two inductors into a single coupled inductor component with a coefficient of coupling greater than 0.99. The first inductor of the first buck converter and the first inductor of the second buck converter are combined into one physically coupled inductor structure. This merging reduces the total component count and simplifies the overall device while maintaining the high coupling necessary for DC current cancellation and improved power efficiency.
3Use of energy by moving object
If two buck converters are operated in parallel with 50% duty cycle each, then power efficiency is improved, but device complexity increases
Solution Approach 1:
The patent employs periodic action by operating two buck converters with complementary duty cycles. Each converter operates at approximately 50% duty cycle in an alternating fashion, with their switching cycles coordinated to minimize ripple current and maximize efficiency. This periodic operation allows both converters to work at optimal efficiency points while sharing the conversion load, improving overall power efficiency despite the increased complexity of coordinating two converter stages.
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 achieves high power efficiency and reduced size and cost by canceling DC currents through the inductor core, allowing for smaller core sizes and lower permeability materials, while improving transient response and reducing power losses.
Implementation Method 1
At least two inductors in communication with the at least two conduction switches, the at least two inductors wound together on a common core and each inductor having a polarity such that DC currents in the inductors cancel each other. The inductors having a coefficient of coupling approximately greater than 0.99.
Implementation Method 2
A first conduction switch in communication with the first inductor of the first buck converter and the second inductor of the second buck converter. A second conduction switch in communication with the second inductor of the first buck converter and the first inductor of the second buck converter.
Data Source
AI summary
A regulator for converting energy from an input source to a voltage of an output. The regulator comprising at least two conduction switches to conduct energy from the input source to the output. Each of the conduction switches operated at approximately 50% duty cycle. At least two inductors in communication with the at least two conduction switches, the at least two inductors wound together on a common core and each inductor having a polarity such that DC currents in the inductors cancel each other. The inductors having a coefficient of coupling approximately greater than 0.99. At least two freewheeling switches in communication with the at least two conduction switches to provide a path for current during non-conduction periods. A drive signal generator to generate drive signals for controlling the at least two conduction switches.