Flyback Converter Signal Coupler Circuit for SR Control
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Solution Overview
Problem
Conventional flyback power converters face issues with size and manufacturing cost due to the use of separate opto-coupler and coupler circuits for signal transmission between the primary and secondary sides, leading to potential short-through conditions and inefficiencies.
Innovation Solution
A flyback power converter with a signal coupler circuit that senses and converts signals between the primary and secondary sides using non-contact coupling, allowing for the same ports to operate in different and non-overlapping time periods, thereby reducing the size and cost while preventing short-through conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate opto-coupler circuit and coupler circuit are used for signal transmission between primary and secondary sides, then signal isolation is ensured, but device size and manufacturing cost increase
Solution Approach 1:
The patent combines the opto-coupler circuit and coupler circuit into a single integrated signal coupler circuit that performs both optical coupling and signal transmission functions. This merging eliminates the need for separate circuits while maintaining signal isolation between primary and secondary sides, thereby reducing device size and component count without compromising reliability
Solution Approach 2:
The integrated signal coupler circuit is designed to perform multiple functions simultaneously: it provides electrical isolation between primary and secondary sides while also transmitting control signals and feedback signals bidirectionally. This multi-functionality replaces what previously required separate dedicated circuits, reducing overall device complexity
2Reliability
If separate opto-coupler circuit and coupler circuit are used, then signal transmission is reliable, but manufacturing cost increases
Solution Approach 1:
By merging two separate circuits into one integrated unit, the patent reduces the total number of components that need to be sourced, assembled, and tested. This consolidation directly lowers manufacturing costs while maintaining the reliable signal transmission function through the integrated design
3Loss of energy
If secondary winding is conductive while primary winding is conductive, then power conversion efficiency increases, but short-through condition occurs causing damage
Solution Approach 1:
The integrated signal coupler circuit provides real-time feedback about the conduction state of both primary and secondary windings to the control circuitry. This feedback mechanism enables the controller to detect when both windings are conductive and immediately adjust switching signals to prevent the harmful short-through condition while optimizing power conversion efficiency
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 the size and manufacturing cost of flyback power converters while preventing short-through conditions by using a single signal coupler circuit for bi-directional signal transmission, ensuring efficient operation and reliability.
Implementation Method 1
a signal coupler circuit coupled between a primary side and a secondary side of a transformer, wherein the signal coupler circuit senses and converts a first signal of the primary side and transmits the converted first signal to the secondary side, and senses and converts a second signal of the secondary side and transmits the converted second signal to the primary side
Data Source
AI summary
A flyback power converter includes a transformer, a power switch, a power switch control circuit, a synchronous rectification (SR) switch, an SR switch control circuit, and a signal coupler circuit. The signal coupler circuit includes a primary port and a secondary port, wherein the primary port is electrically connected to the power switch control circuit, and the secondary port is electrically connected to the SR switch control circuit. The primary port and the secondary port receive different signals generated by the power switch control circuit and the SR switch control circuit respectively, and the signal coupler circuit senses and converts the different signals to generate corresponding converted signals at the secondary port and the primary port respectively in different and non-overlapping time periods, without direct contact or direct connection between the primary side and the secondary side of the transformer.