Isolated DC-DC Converter with Current Tripler Rectifier
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Solution Overview
Problem
Conventional DC-to-DC converters face challenges in high current applications due to high current and thermal stresses, bulky inductor size, and inflexibility in PCB layout designs, particularly in microprocessor and telecommunication systems where high power density and efficient thermal management are required.
Innovation Solution
The introduction of a current tripler rectification topology, where three output filter inductors evenly share the load current, reducing current and thermal stress, and improving transformer utilization, allowing for better power dissipation and thermal management, and simplifying magnetic design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single output filter inductor is used to carry full load current, then the converter structure is simple, but the inductor suffers high current and thermal stresses resulting in bulky inductor size
Solution Approach 1:
The patent divides the single output filter inductor into multiple parallel inductors (first and second output filter inductors). Each inductor carries a portion of the total load current, reducing the current and thermal stress on individual inductors. This segmentation allows for smaller, more manageable inductor sizes while maintaining the same total current handling capability.
2Device complexity
If a single output filter inductor carries full load current, then the converter structure is simple, but the inductor size becomes bulky leading to inflexibility in PCB layout
Solution Approach 1:
The patent segments the single large inductor into multiple smaller parallel inductors. This reduces the footprint area of each individual inductor, providing greater flexibility for PCB layout design and reducing the overall space required while maintaining the same current handling capability.
3Ease of operation
If transformer secondary windings are used in center-tapped rectifier, then bi-directional current flow is achieved, but one winding conducts full load current for half the switching period resulting in inefficient utilization
Solution Approach 1:
The patent segments the transformer secondary winding into multiple parallel windings, each handling a portion of the load current. This distributes the conduction loss across multiple windings, improving overall transformer utilization efficiency while maintaining bi-directional current flow capability.
4Productivity
If high switching frequency is used to improve power density, then conversion efficiency and thermal management become restrictions, but secondary-side conduction loss dominates overall power loss
Solution Approach 1:
The patent segments the load current across multiple parallel output filter inductors, reducing the conduction loss in each inductor. This reduces the dominant secondary-side conduction loss, improving overall conversion efficiency and enabling better thermal management at high switching frequencies.
Solution Approach 2:
The patent changes the electrical parameters by introducing multiple parallel inductor paths, which reduces the effective resistance and conduction loss. This parameter change enables high switching frequency operation with improved efficiency and thermal characteristics.
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
This approach results in improved power density, reduced inductor copper loss, and enhanced thermal management, making it more suitable for high current applications with increased efficiency and flexibility in design.
Implementation Method 1
a transformer with a primary side winding and a secondary side winding
Implementation Method 2
three output filter inductors evenly share the load current
Data Source
AI summary
A DC-to-DC converter having a transformer with a primary and a tapped secondary, two serial output filter inductors connected parallel with the secondary, a center output filter inductor connected between the secondary tap and serial output inductors, two serially connected switches connected in parallel with the two output inductors for receiving a signal to control operation of the switches during steady state and an output load connected between the serial connection of the serial output inductors and serial switching devices. The transformer primary side connected with double-ended primary-side topologies. The transformer secondary and output filers configured to form a current tripler rectifier, current quadtupler rectifier or current N-tuper rectifier. The output filter inductors evenly share output current resulting in reduction of current and thermal stress during high current application and the rectification topology has simple driving for synchronous rectifier application without increasing complexity of control and operation of primary-side topologies.