Asymmetrical Hybrid DC-DC Converter With Multi-Path Inductor Switching
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Solution Overview
Problem
Existing power conversion systems, such as buck converters and charge-pump converters, suffer from inefficiencies and are unsuitable for high power demands, leading to excessive heat generation and limited charging capabilities in devices like smart watches and AI-based computing systems.
Innovation Solution
A hybrid DC-DC converter design utilizing multiple low-voltage FETs and multiple current paths through an inductor, with a specific switching sequence to reduce power loss and increase efficiency, allowing for higher input voltages and currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If buck converters are used for power conversion, then high current can be delivered, but power conversion efficiency is limited to no greater than 85%
Solution Approach 1:
The power conversion function is divided into two separate conversion stages: first a high-voltage to medium-voltage conversion stage, then a medium-voltage to low-voltage conversion stage. This segmentation allows each stage to operate at optimized voltage levels, achieving over 90% efficiency in each stage while delivering high output current, thereby resolving the contradiction between high power delivery and energy loss.
2Loss of energy
If charge-pump converters are used, then power conversion efficiency can reach 99%, but they are not suitable for output currents in excess of 2A
Solution Approach 1:
The power conversion is segmented into two stages with different converter types optimized for different current ranges. The first stage (high-voltage to medium-voltage) uses a converter suitable for high voltage operation, while the second stage (medium-voltage to low-voltage) uses a converter optimized for high current delivery. This segmentation enables the system to achieve both high efficiency and high output current capability, overcoming the 2A current limit of single-stage charge-pump converters.
3Loss of energy
If multiple channels are used to increase power efficiency, then each channel can supply relatively small current with better efficiency, but the PCB area occupied becomes prohibitive
Solution Approach 1:
Instead of increasing the number of parallel channels (horizontal expansion), the invention transitions to a two-stage conversion architecture (vertical expansion in the voltage domain). This dimensional change allows achieving high efficiency through optimized voltage conversion ratios in each stage without requiring multiple parallel channels, thereby reducing PCB area while maintaining or improving power conversion efficiency.
4Productivity
If high input voltage is used in DC/DC converter, then high current can be supplied to battery for fast charging, but heat generation increases making devices uncomfortable
Solution Approach 1:
The voltage conversion is segmented into two stages: first converting high input voltage to medium voltage, then converting medium voltage to low battery voltage. This segmentation reduces the voltage conversion ratio per stage, lowering the current magnitude at each stage and thereby reducing I²R heat losses. The result is fast charging capability maintained while device temperature remains comfortable for users.
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 hybrid DC-DC converter achieves improved efficiency by reducing power loss and heat generation, enabling faster charging and cooler operation of devices, particularly suitable for high-power applications like AI-based computing systems.
Implementation Method 1
multiple current paths through an inductor
Implementation Method 2
low-voltage FETs and multiple current paths
Data Source
AI summary
Systems for hybrid DC-DC voltage conversion are disclosed. One aspect includes an electrical circuit configured to perform a DC-DC voltage conversion between an input voltage and an output voltage. The electrical circuit includes a first electrical network that includes seven switching transistors and two flying capacitors, and a second electrical network that includes six switching transistors and one flying capacitor. The first electrical network and the second electrical network may be interconnected at least at each of an input node, an output node, and a switching node. Two switching transistors of the six switching transistors in the second electrical network may further connect the first electrical network and the second electrical network. The electrical circuit may include a magnetic reactive component connected between the switching node and the output node. The DC-DC voltage conversion may involve a repeating cycle of six distinct switching system states.