Power FET Gate Charge Recovery for Switching Regulators

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Solution Overview

Problem

Switching regulators face efficiency limitations at higher switching frequencies due to transitional and gate charge losses, particularly when dealing with high input voltages like 12 volts, which restricts the use of smaller components and increases electromagnetic interference.

Innovation Solution

Implementing a gate charge recovery mechanism in switching regulators, where a portion of the gate charge is recovered during each switching cycle and stored in external capacitors, allowing the regulator to operate at higher frequencies without significant efficiency penalties, applicable to both asynchronous and synchronous switching circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If switching frequency is increased, then the size of external components (inductors and capacitors) is reduced and EMI is reduced, but transitional losses and gate charge losses increase linearly

Engineering Contradiction:
Improvesize of external componentsVSAvoidtransitional losses and gate charge losses
Core Design Contradiction:
Volume of moving objectVSLoss of energy

Solution Approach 1:

The patent recovers gate charge energy that would otherwise be dissipated during each switching cycle. By capturing the energy stored in the gate capacitance of the power FET when the transistor turns off and storing it in a recovery capacitor, the system recovers a substantial portion of the gate charge loss. This recovered energy is then reused to drive the gate in subsequent cycles, significantly reducing the net energy loss at high switching frequencies.

Inventive Principle:
Principle #34Discarding and recovering

2Power

If input voltage is increased to 12 volts, then power delivery capability is improved, but gate charge losses increase making it difficult to achieve efficiency at high switching frequencies

Engineering Contradiction:
Improvepower delivery capabilityVSAvoidgate charge losses
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The patent converts the harmful effect of high input voltage causing increased gate charge losses into a benefit. By using the high voltage to charge the gate capacitance and then recovering this energy through the gate charge recovery circuit, the system transforms the energy that would be wasted as heat into reusable energy. This allows the system to maintain high power delivery capability at 12 volts while achieving high efficiency even at elevated switching frequencies.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If switching frequency is increased to 500 kilohertz, then regulator efficiency should improve with smaller components, but gate charge losses make it difficult to achieve efficiency

Engineering Contradiction:
Improveswitching frequencyVSAvoidgate charge losses
Core Design Contradiction:
ProductivityVSLoss of energy

Solution Approach 1:

The patent implements continuous gate charge recovery and reuse throughout the switching operation. The recovery capacitor continuously accumulates gate charge energy from each switching cycle and continuously supplies this recovered energy back to the gate driver. This continuous cycle of recovery and reuse ensures that the beneficial effects of high switching frequency (smaller components, reduced EMI) are achieved without the penalty of increased gate charge losses, maintaining high efficiency at 500 kHz and above.

Inventive Principle:
Principle #20Continuity of useful 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 gate charge recovery significantly reduces power losses, enabling switching regulators to operate at higher frequencies with improved efficiency, reducing the size of components and minimizing electromagnetic interference, with potential savings of up to 60-80% in total gate charge loss.

Implementation Method 1

a first capacitor coupled between a regulated voltage supply and a gate terminal of an output transistor in a switching circuit

Methodology Applied
Scientific EffectCapacitance: Capacitance

Implementation Method 2

a switch arranged to provide a bypass path from the gate terminal to the capacitor when the output transistor is turned off

Methodology Applied
Scientific EffectElectrical charge flow: Conduction (electrical)

Data Source

PatentUS8278886B2Power FET gate charge recovery
Publication Date: 2012.10.02 NAT SEMICON CORP
  • US8278886B2 patent drawing
  • US8278886B2 patent drawing
  • US8278886B2 patent drawing

AI summary

A circuit for recovering charge at the gate of an output transistor arranged to drive the output of a switching circuit such as a switching regulator or controller. A substantial portion of the charge for each switching cycle is recovered under a wide range of load conditions for the switching circuit, e.g., no load, partial load, or full load. Also, charge recovery operates effectively with a switching circuit that is arranged to switch in a synchronous or asynchronous manner. Additionally, if the output voltage of a switching circuit is 12 or more volts, the amount of charge that can be saved can be relatively substantial.