Bi-Directional DC/DC Converter Backplane Layout for Balanced Resistance
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Solution Overview
Problem
Current DC/DC converter systems for charging and testing rechargeable batteries face inefficiencies due to high copper resistance, which limits current capacity and flexibility in high power density designs, particularly in converting high voltage low current to low voltage high current, and struggles with rapid current direction changes.
Innovation Solution
A bi-directional DC/DC converter with a copper backplane and strategically placed MOSFET circuits to achieve balanced resistance and efficient conversion, allowing for rapid control of high voltage low current to low voltage high current conversion, utilizing a linear arrangement of converter stages without imbalance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional AC to high voltage DC conversion is used, then power transmission efficiency is improved, but conversion to low voltage high current for battery charging results in significant copper resistance losses
Solution Approach 1:
The patent changes the voltage/current parameters by implementing a bi-directional DC/DC converter that operates optimally in low voltage high current mode, eliminating the traditional high voltage intermediate stage and directly converting between battery voltage and charger voltage, thereby reducing copper resistance losses while maintaining high current capacity
Solution Approach 2:
The patent replaces the mechanical/electrical transformation chain (AC to high voltage DC to low voltage DC) with a direct electronic conversion system using synchronous rectification and bi-directional DC/DC conversion, substituting multi-stage conversion with a streamlined electronic process that reduces resistive losses
2Reliability
If multiple interleaved power stages are used to reduce current ripple, then current ripple is reduced, but system volume and complexity increase
Solution Approach 1:
The patent segments the power conversion function into modular components (synchronous rectification stage, bi-directional DC/DC conversion stage) that can be independently optimized and arranged, achieving current ripple reduction without requiring multiple large interleaved stages
Solution Approach 2:
The patent transitions from linear conversion topology to a bi-directional conversion architecture, enabling power flow in both directions and allowing more flexible current management that reduces ripple without increasing volume
3Volume of stationary object
If linear arrangement of power stages is used, then volume is reduced compared to circular arrangement, but resistance imbalance occurs between stages
Solution Approach 1:
The patent applies local quality by optimizing the electrical path lengths and impedance matching at each specific connection point in the linear arrangement, ensuring that each power stage experiences balanced effective resistance despite the linear topology, thereby maintaining stability without increasing volume
4Productivity
If high current capacity is achieved, then charging speed is improved, but system size and weight increase
Solution Approach 1:
The patent changes the operational parameters by enabling bi-directional power flow and synchronous rectification, allowing the system to achieve high current capacity with optimized component sizing that reduces overall weight while maintaining charging speed
Solution Approach 2:
The patent implements a bi-directional converter that can operate in multiple modes (charging, discharging, power factor correction), allowing a single lightweight system to perform multiple functions that would otherwise require separate heavier systems
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
Enables efficient conversion of up to 300 amps with rapid current adjustments and direction changes, improving charging and testing capabilities while minimizing size and weight, achieving high efficiency and flexibility.
Implementation Method 1
a copper backplane having a first side and a second side, the first side providing first power terminals and second power terminals through the backplane
Implementation Method 2
three distinct pairs of MOSFET circuits disposed between the input points and the output points... converting high voltage low current to low voltage high current
Data Source
AI summary
Provided is a system and method for a bi-directional DC/DC converter. More specifically, provided is a bi-directional DC/DC converter, having a balancing effect of two bi-directional input points and two bi-directional output points to three distinct pairs of MOSFET circuits disposed between the input points and the output points. The balancing effect is provided by a copper backplane having a first side and a second side, the first side providing first power terminals and second power terminals through the backplane the second side providing electrical traces disposing two pairs of MOSFETS each at a first proximity to either of the first power terminals or the second power terminals with a first effective resistance and the third pair of MOSFETS at a second proximity between the first power terminals and the second power terminals with a second effective resistance, wherein the first effective resistance is substantially the same as the second effective resistance. An associated method of use is also provided.