DC Voltage Conversion Circuit Using Segmented Transformers

Solution Overview

Problem

Existing DC voltage conversion circuits face challenges in miniaturization and efficiency due to increased current demands in electric vehicles, leading to higher losses and larger magnetic components, particularly in transformers and coils.

Innovation Solution

A DC voltage conversion circuit with a series connection of transformers and rectifier diodes, where a controller alternately controls switches to manage current flow, accumulating energy in transformers with specific permeability ranges to reduce magnetization saturation and energy loss, thereby enabling miniaturization and high efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a single-output circuit supplies large current, then power delivery capability is improved, but magnetic component size increases and conversion efficiency deteriorates

Engineering Contradiction:

Improvepower delivery capabilityVSAvoidconversion efficiency

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent divides the single-output circuit into two separate output circuits (first output circuit with first transformer and first rectifier diode, second output circuit with second transformer and second rectifier diode). Each transformer handles alternating current cycles, with energy accumulation occurring in one transformer during the other's discharge phase. This segmentation distributes the power delivery load, reducing the current burden on individual magnetic components and minimizing energy losses.

Inventive Principle:

Principle #1Segmentation

2Power

If a single-output circuit supplies large current, then power delivery capability is improved, but magnetic component size increases

Engineering Contradiction:

Improvepower delivery capabilityVSAvoidmagnetic component size

Core Design Contradiction:

PowerVSVolume of stationary object

Solution Approach 1:

The patent divides the single-output circuit into two separate output circuits (first output circuit with first transformer and first rectifier diode, second output circuit with second transformer and second rectifier diode). Each transformer handles alternating current cycles, with energy accumulation occurring in one transformer during the other's discharge phase. This segmentation distributes the power delivery load, reducing the current burden on individual magnetic components and minimizing energy losses.

Inventive Principle:

Principle #1Segmentation

3Power

If high current flows through transformer and coil in series, then power delivery is improved, but energy loss increases due to series transmission

Engineering Contradiction:

Improvepower deliveryVSAvoidenergy loss

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent divides the single-output circuit into two separate output circuits (first output circuit with first transformer and first rectifier diode, second output circuit with second transformer and second rectifier diode). Each transformer handles alternating current cycles, with energy accumulation occurring in one transformer during the other's discharge phase. This segmentation distributes the power delivery load, reducing the current burden on individual magnetic components and minimizing energy losses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller performs on/off control alternately to the first switch and second switch, creating periodic action where current flows through the first transformer during one cycle and through the second transformer during the next cycle. This alternating periodic operation allows each transformer to accumulate energy during its active phase and release it during the other's phase, reducing continuous high current flow and associated energy losses.

Inventive Principle:

Principle #19Periodic action

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 effectively reduces energy loss and minimizes transformer size, achieving efficient and compact DC voltage conversion while maintaining high power handling capabilities.

Implementation Method 1

a first state in which the first switch is turned on with current flowing in the rectification direction of the first rectifier diode in the first output circuit, accumulating electrical energy in the second transformer; and a second state in which the second switch is turned on with current flowing in the rectification direction of the second rectifier diode in the second output circuit, accumulating electrical energy in the first transformer, alternately

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a first output circuit includes: a secondary side of the first transformer and a first rectifier diode electrically connected in series with the secondary side of the first transformer

Methodology Applied

Scientific EffectRectification: Diode

Data Source

PatentUS11581818B2DC voltage conversion circuit and power supply device

Publication Date: 2023.02.14 DIAMET CORP

AI summary

A direct-current voltage conversion circuit having on/off control with a dead-time period performed alternately on a first switch and a second switch included in a direct-current voltage conversion circuit. When alternating current flows in a series circuit part including two transformers magnetically independent, current flows in an output circuit including a secondary side of one transformer, and energy is accumulated in the other transformer. The permeabilities of the magnetic cores in the first and second transformers is between 15 and 120.