Dual-Transformer DC-to-DC Converter Voltage Segmentation
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Solution Overview
Problem
Existing dual-transformer DC-to-DC converters require high-breakdown voltage switching elements, leading to increased manufacturing costs and switching losses due to high ON-state resistance, and necessitate the use of multiple switching elements in parallel, which complicates the cooling mechanism and increases the size and weight of the apparatus.
Innovation Solution
A dual-transformer DC-to-DC converter with a symmetrical first AC/DC conversion circuit using switching elements with lower breakdown voltage levels, connected in parallel with return current diodes to reduce voltage surges, and employing capacitors of smaller size to minimize voltage development, thereby reducing the breakdown voltage requirements and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-breakdown voltage switching elements are used, then the converter can handle high voltages, but the manufacturing cost increases and switching losses increase due to high ON-state resistance
Solution Approach 1:
The patent divides the high-voltage handling function across multiple switching elements connected in series, where each element only needs to withstand a portion of the total voltage. This segmentation allows using lower-breakdown-voltage elements (reducing cost and switching losses) while still achieving the required overall voltage capability through series connection.
2Reliability
If high-breakdown voltage switching elements are used, then the converter can handle high voltages, but the apparatus size and weight increase due to thicker low impurity-concentration material layers
Solution Approach 1:
By segmenting the voltage handling requirement across multiple switching elements in series, each element can use thinner material layers with lower impurity concentration, reducing the overall material volume and apparatus weight while maintaining the required voltage capability.
3Power
If multiple switching elements are connected in parallel to achieve required current, then the current capacity is sufficient, but the cooling mechanism becomes more complex and the apparatus size increases
Solution Approach 1:
The patent segments the current handling function across multiple switching elements connected in parallel, where each element handles a portion of the total current. This segmentation allows using elements with lower current ratings individually, reducing the need for complex cooling mechanisms for each element while achieving the required total current capacity.
4Reliability
If high-breakdown voltage switching elements are used, then the converter can handle high voltages, but the manufacturing cost increases
Solution Approach 1:
By segmenting the voltage handling requirement across multiple switching elements in series, each element can be manufactured with lower breakdown voltage specifications, which are cheaper to produce. This segmentation strategy reduces the overall manufacturing cost while maintaining the required high-voltage capability.
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 reduces switching losses, manufacturing costs, and apparatus size by utilizing lower breakdown voltage switching elements and capacitors, achieving higher efficiency and stability while minimizing ripple in the output DC power, allowing for a more compact and lightweight design.
Implementation Method 1
the transformer actions of the two transformers (i.e., outputting of current to the secondary windings)
Implementation Method 2
a capacitor is used to transfer current between the primary windings and the primary-side power source, with charge storage by the capacitor serving to achieve a 'soft switching' effect
Data Source
AI summary
A first AC/DC converter circuit is coupled via two transformers to a second AC/DC converter circuit, the first AC/DC converter circuit having a symmetrical configuration of two switching elements performing complementary opened/closed switching, to alternately connect positive and negative terminals of a DC source to a junction between transformer primary windings. Each primary winding alternates between a condition of transferring electrical power to a secondary winding and a condition of serving as a choke coil which temporarily stores electromagnetic energy when a current flows through that primary winding and a primary winding of the other transformer.