High-Frequency Power Factor Correction Converter
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Solution Overview
Problem
Conventional power converters for supplying DC loads from a single-phase AC grid face challenges in size and cost due to large and expensive magnetic energy storage components, operating at low switching frequencies with low power densities and efficiency.
Innovation Solution
The development of high-frequency power converter designs with reconfigurable rectifiers, voltage balancers, and resonant-transition buck converters that reduce the size of magnetic components and increase efficiency, utilizing semiconductor devices with low capacitance and operating at frequencies above 1 MHz.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power converters operate at low switching frequencies (200 kHz or below), then magnetic energy storage components can be used, but the size and cost of the converter increases due to large magnetic components
Solution Approach 1:
The patent applies parameter changes by increasing the switching frequency from conventional 200 kHz or below to high frequencies above 1 MHz. This fundamental parameter change enables the use of smaller magnetic energy storage components while maintaining reliable power converter operation, directly resolving the contradiction between operational reliability and component size.
2Power
If conventional power converters use large magnetic energy storage components, then power conversion can be achieved, but the physical size and cost of the converter increases
Solution Approach 1:
The patent changes the operating frequency parameter to above 1 MHz, which enables significant reduction in magnetic component size while maintaining full power conversion capability. This parameter change allows the converter to process the same power levels with much smaller physical footprint.
Solution Approach 2:
The patent employs a reconfigurable rectifier with multiple output ports that can be selectively activated. This segmentation allows different converter modules to share the power conversion load, enabling each module to operate at optimal high frequency with reduced magnetic component requirements while collectively handling the full power conversion task.
3Power
If conventional power converters operate at low switching frequencies, then magnetic components can be used, but the power density decreases
Solution Approach 1:
The patent increases the switching frequency parameter to above 1 MHz, which directly enables higher power density by allowing magnetic energy storage components to be significantly smaller for the same power handling capability, thus increasing power per unit volume.
4Power
If conventional power converters use large magnetic components, then power conversion is achieved, but the cost increases
Solution Approach 1:
The patent changes the operating frequency to above 1 MHz, which reduces the size and cost of magnetic components. High-frequency operation allows the use of smaller, less expensive magnetic materials and reduces the overall bill of materials cost while maintaining power conversion capability.
Solution Approach 2:
The reconfigurable rectifier with multiple output ports provides multi-functionality, allowing a single converter design to serve multiple power levels and configurations. This universality reduces development costs and allows standardized high-frequency modules to be used across different power requirements, lowering overall system cost.
Data Source
AI summary
A circuit includes a reconfigurable rectifier, a voltage balancer, and a pair of converters. The reconfigurable rectifier includes an ac input port and three output ports. In a first configuration, the reconfigurable rectifier can deliver power at a first output port and, in a second configuration, to at least a second output port. The voltage balancer includes first and second ports coupled to second and third output ports of the reconfigurable rectifier and is configured to balance received voltage at the first and second ports. The first converter has an input coupled to the first port of the voltage balancer and an output at which a first converted voltage signal is provided. The second converter has an input coupled to the second port of the voltage balancer and an output at which a second converted voltage signal is provided.