Energy Refeeding Transformer for Rectangular Plasma Voltage Pulses

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Solution Overview

Problem

Plasma treatment applications require high voltage, high frequency, rectangular, asymmetrical, pulsed voltage supplies that exceed the voltage handling capabilities of individual semiconductor switches, leading to inefficiencies and unwanted voltage oscillations due to series connection and capacitive load charging/discharging processes.

Innovation Solution

An energy refeeding module with a rectifying circuit and transformer is used to connect to a DC voltage source, featuring low stray inductance and parasitic resistance, allowing for high voltage, high current, and fast voltage rise, with a secondary winding connected to the rectifying circuit to generate nearly ideal rectangular voltage pulses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If series connection of semiconductor switches is used to achieve high voltage, then voltage handling capability is improved, but device complexity and efficiency deteriorate due to voltage balancing requirements and unwanted oscillations

Engineering Contradiction:
Improvevoltage handling capabilityVSAvoidvoltage balancing means
Core Design Contradiction:
Stress or pressureVSDevice complexity

Solution Approach 1:

A transformer is introduced as an intermediary component between the DC voltage source and the switching circuit. The transformer's primary winding connects to the switching unit while the secondary winding connects to the rectifying circuit, which in turn connects to the DC voltage source. This intermediary transformer structure enables high voltage generation through electromagnetic induction without requiring series connection of switches, thereby eliminating the need for complex voltage balancing means.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical/electrical series connection of semiconductor switches with a magnetic field-based transformer system. Instead of directly connecting multiple switches in series to achieve high voltage, the system uses electromagnetic induction in the transformer to step up the voltage, substituting the direct electrical connection approach with a field-based energy transfer mechanism.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Stress or pressure

If series connection of switches is used for high voltage operation, then voltage capability is improved, but unwanted voltage oscillations increase

Engineering Contradiction:
Improvevoltage capabilityVSAvoidvoltage oscillations
Core Design Contradiction:
Stress or pressureVSObject-generated harmful factors

Solution Approach 1:

The transformer acts as an intermediary that isolates the switching circuit from the high voltage output. By using electromagnetic induction through the transformer windings, the system generates high voltage without directly exposing the switching elements to oscillatory high voltage conditions, thereby reducing unwanted voltage oscillations.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Productivity

If pulse-by-pulse charging and discharging of capacitive load is performed, then plasma processing is enabled, but significant power loss occurs

Engineering Contradiction:
Improveplasma processing capabilityVSAvoidpower loss
Core Design Contradiction:
ProductivityVSLoss of energy

Solution Approach 1:

The energy refeeding module enables continuous energy transfer to the capacitive plasma load. Instead of discrete pulse-by-pulse charging and discharging, the transformer and rectifying circuit provide continuous energy replenishment to the load capacitance, maintaining plasma processing while significantly reducing the power loss associated with repeated charging cycles.

Inventive Principle:
Principle #20Continuity of useful action

Solution Approach 2:

The energy refeeding module recovers and reuses energy that would otherwise be lost during the plasma processing cycles. The transformer and rectifying circuit capture residual energy from the capacitive load and feed it back into the system, reducing overall power consumption while maintaining continuous plasma processing capability.

Inventive Principle:
Principle #34Discarding and recovering

4Device complexity

If individual semiconductor switches are used, then device simplicity is improved, but voltage handling capability deteriorates

Engineering Contradiction:
Improveswitching circuit simplicityVSAvoidvoltage handling capability
Core Design Contradiction:
Device complexityVSStress or pressure

Solution Approach 1:

The transformer serves as an intermediary that enables voltage transformation without requiring complex series connections of switches. The primary winding connects to simple switching elements while the secondary winding provides the high voltage output, maintaining switching circuit simplicity while achieving high voltage handling capability through electromagnetic induction.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 prevents unwanted voltage oscillations and increases efficiency by reducing power loss during capacitive load charging and discharging, ensuring high power delivery to plasma processing loads.

Implementation Method 1

a transformer (1510) comprising: a primary winding (1511) configured to be connected in series between the switching unit (15010) and an output (15005) of the energy refeeding module (15001), and configured to have both a stray inductance and parasitic resistance low enough to lead the one or a combination of the following: the high value of voltage, the high value of voltage rise, and the high current value

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250210306A1Energy refeeding module, switching circuit and embodiment, plasma processing system, and a method of producing rectangular voltage output pulses for a plasma processing load
Publication Date: 2025.06.26 TRUMPF HUETTINGER SP ZOO
  • US20250210306A1 patent drawing
  • US20250210306A1 patent drawing
  • US20250210306A1 patent drawing

AI summary

An energy refeeding module for a switching circuit with a switching unit configured to be connectable to a DC voltage source includes a rectifying circuit configured to be connected with a positive end of a DC-side thereof to a positive connection of the DC voltage source, with a negative end of the DC-side thereof to a negative connection of the DC voltage source, and a transformer. The transformer includes a primary winding configured to be connected in series between the switching unit and an output of the energy refeeding module, and configured to have both a stray inductance and parasitic resistance low enough to lead one or a combination of the following: the high value of voltage, the high value of voltage rise, and the high current value. The transformer includes a secondary winding connected to an AC-side of the rectifying circuit.