Flying-Capacitor DC-DC Converter for High-Voltage High-Power Control

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Solution Overview

Problem

Conventional DC-DC resonant converters struggle to simultaneously meet the demands of high input voltage and high-power applications.

Innovation Solution

The DC-DC converter incorporates pairs of flying capacitors and subcircuits, allowing for the adjustment of switching frequency to control the DC output voltage, suitable for high input voltage and high-power applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional DC-DC resonant converter topology is used, then the structure is simple and operation is easy, but it cannot simultaneously meet high input voltage and high-power application requirements

Engineering Contradiction:
Improvecapability to meet high input voltage and high-power requirementsVSAvoidconverter structure complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The converter is divided into multiple modular units including N upper switches, N lower switches, N pairs of flying capacitors, and N subcircuits. Each module can be independently configured and connected in series/parallel combinations, allowing the system to be scaled and adapted for high voltage and high power applications while maintaining manageable complexity through standardization

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The converter employs dynamic switching of the N upper and lower switches with adjustable switching frequency. The switching pattern and frequency can be dynamically controlled to optimize performance for different operating conditions, enabling the converter to adapt to high input voltage and high-power requirements while maintaining simple operational control

Inventive Principle:
Principle #15Dynamics

2Measurement precision

If switching frequency is adjusted to control DC output voltage, then output voltage control precision is improved, but switching losses increase

Engineering Contradiction:
ImproveDC output voltage control precisionVSAvoidswitching losses
Core Design Contradiction:
Measurement precisionVSLoss of energy

Solution Approach 1:

The converter uses periodic switching of the N upper and lower switches at a controlled frequency. By adjusting the switching frequency and duty cycle in a periodic manner, precise DC output voltage control is achieved while the resonant nature of the circuit minimizes switching losses through soft switching conditions

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The converter changes the switching frequency parameter to control the DC output voltage. The N pairs of flying capacitors and subcircuits are configured to resonate at different frequencies, allowing voltage control through frequency adjustment while maintaining efficient operation by staying within optimal switching ranges that minimize losses

Inventive Principle:
Principle #35Parameter changes

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 converter effectively handles high input voltage and high-power applications by optimizing the connection of flying capacitors and subcircuits, enhancing its suitability for such demanding conditions.

Implementation Method 1

The resonant converter includes a resonant-tank circuit for shaping the switch voltage and/or the current waveform to minimize switching losses and allow high-frequency operation

Methodology Applied
Scientific EffectResonance: Resonance

Implementation Method 2

The DC-DC converter receives a DC input voltage from a voltage source and converts it to a DC output voltage through N upper switches, N lower switches, N pairs of flying capacitors and N subcircuits

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250385604A1DC-DC converter
Publication Date: 2025.12.18 DELTA ELECTRONICS INC(CN)
  • US20250385604A1 patent drawing
  • US20250385604A1 patent drawing
  • US20250385604A1 patent drawing

AI summary

A DC-DC converter includes N upper switches, N lower switches, N pairs of flying capacitors and N subcircuits. The N lower switches are electrically connected between the N upper switches and the second terminal of the voltage source. A n-th pair of flying capacitors is coupled between a common node between the n-th and (n+1)-th upper switches and a common node between the n-th and (n+1)-th lower switches. A N-th pair of flying capacitors is coupled with the N-th upper switch and the N-th lower switch. A first subcircuit is coupled between a common node between the first upper switch and the first lower switch and a middle node of a first pair of flying capacitors. A i-th subcircuit is coupled between a middle node of a (i−1)-th pair of flying capacitors and a middle node of a i-th pair of flying capacitors.