DC Voltage Conversion Device Series-Parallel Transformer Topology
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Solution Overview
Problem
Conventional DC-DC converters have large, cumbersome transformers with high copper loss and inconvenient layouts, making them difficult to fabricate and treat thermally, and they struggle to uniformly output high currents at high power levels.
Innovation Solution
The DC voltage conversion device connects the primary sides of transformers in series and the secondary sides in parallel, using multiple transformers and a rectifying device with equal conductive wire lengths to reduce copper loss and facilitate heat treatment, allowing for easier production of Litz wires and uniform current output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single transformer with high output voltage is used, then the output power can be achieved, but the transformer size becomes large and layout becomes difficult
Solution Approach 1:
The patent divides a single high-power transformer into multiple lower-power transformers (at least two first transformers, at least two second transformers, at least two third transformers). Each transformer handles a portion of the total power, reducing individual transformer size and making layout easier while maintaining the required total output power through parallel connection of secondary sides
2Power
If a single transformer with high output voltage is used, then the output power can be achieved, but the copper loss increases
Solution Approach 1:
By segmenting the power transformation into multiple transformers with parallel secondary connections, the current in each transformer is reduced compared to a single transformer handling the full power. Since copper loss is proportional to the square of the current (I²R), this segmentation significantly reduces total copper loss while maintaining the required output power
3Loss of energy
If Litz wires with small diameter are used, then the current density requirement is met, but the wires are difficult to produce
Solution Approach 1:
The patent reduces the current density requirement by distributing the total current across multiple parallel transformer windings. This allows the use of thicker, easier-to-manufacture Litz wires in each transformer while still meeting the overall current density requirements, as each individual winding carries only a fraction of the total current
4Ease of operation
If the primary sides of transformers are connected in parallel, then the current distribution is easier, but the voltage conversion ratio becomes difficult to control
Solution Approach 1:
Instead of connecting primary sides in parallel (which simplifies current distribution but complicates voltage control), the patent inverts the approach by connecting primary sides in series and secondary sides in parallel. This configuration allows the primary series connection to easily control the voltage conversion ratio through turns ratio, while the secondary parallel connection naturally distributes current based on impedance matching
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 configuration reduces copper loss and enables uniform high current output while minimizing transformer size and complexity, making it easier to fabricate and treat thermally, thus achieving efficient high-power conversion.
Implementation Method 1
The DC voltage conversion device includes a resonate driving device, at least two first transformers, at least two second transformers, at least two third transformers, and a rectifying device
Implementation Method 2
The rectifying device is coupled to the first output, the third output, and the fifth output
Data Source
AI summary
A direct-current (DC) voltage conversion device includes a resonate driving device, at least two second transformers, at least two second transformers, at least two third transformers, and a rectifying device. The primary sides of the second transformers are connected in series via a first conductive wire and coupled to the resonate driving device via a second conductive wire. The primary sides of the second transformers are connected in series via a third conductive wire and coupled to the resonate driving device via a fourth conductive wire. The primary sides of the third transformers are connected in series via a fifth conductive wire and coupled to the resonate driving device via a sixth conductive wire. The rectifying device is coupled to the secondary sides of the transformers.