Integrated Current-Doubler Rectifier for High-Current PCB-Dense Converters
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Solution Overview
Problem
In high-current, low-voltage applications, existing converter circuits face challenges in achieving high efficiency and low cost while maintaining high printed circuit board (PCB) density, particularly due to the limitations of transformer secondary windings in meeting output current requirements.
Innovation Solution
The proposed converter circuit incorporates a bridge circuit, a transformer with a secondary winding split into two portions, and a half-bridge current-doubler rectifier. This configuration allows for direct input current transfer through the primary winding, reducing current through the secondary winding and switches, and employs the transformer's secondary winding for current doubling without discrete inductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If discrete inductors are used to increase secondary current, then output current requirement is met, but device complexity and cost increase
Solution Approach 1:
The patent combines the functions of the secondary winding and discrete inductors into a single integrated transformer structure. The secondary winding is configured with two portions that perform both voltage transformation and current doubling functions, eliminating the need for separate discrete inductors and reducing overall circuit complexity while meeting high output current requirements.
Solution Approach 2:
The secondary winding is designed to perform multiple functions simultaneously: voltage transformation from primary to secondary side, and current doubling through its specific configuration with two portions. This multi-functional design eliminates the need for separate dedicated inductors, reducing component count and circuit complexity.
2Quantity of substance
If more discrete inductors are added for current doubling, then output current increases, but PCB density decreases
Solution Approach 1:
The patent merges the current-doubling function into the transformer's secondary winding structure itself. By configuring the secondary winding with two portions that are magnetically coupled to the primary winding, the circuit achieves current doubling without requiring separate discrete inductors, thereby minimizing PCB footprint and maximizing PCB density.
3Quantity of substance
If transformer secondary winding has more turns for high current, then output current increases, but voltage scaling capability decreases
Solution Approach 1:
The secondary winding is segmented into two distinct portions that are magnetically coupled to the primary winding. This segmentation allows the transformer to maintain proper turns ratio for voltage scaling while the specific configuration of the two portions enables current doubling, thus preserving both voltage transformation capability and high current output.
Solution Approach 2:
The patent introduces a new dimensional aspect to the transformer design by configuring the secondary winding with two portions that operate in parallel magnetic paths. This dimensional change in the winding structure enables simultaneous achievement of voltage scaling (through turns ratio) and current doubling (through the parallel path configuration), resolving the trade-off between these two functions.
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 achieves high efficiency and low cost by reducing voltage stress on primary side devices, minimizing the number of discrete inductors needed, and increasing PCB density, while effectively meeting high output current requirements.
Implementation Method 1
The transformer comprises a primary winding and a secondary winding... the primary winding having a first end that is connected to the first bridge node and a second end that is connected to the second bridge node
Implementation Method 2
The half-bridge current-doubler rectifier comprises the first portion of the secondary winding as a first inductor and the second portion of the secondary winding as a second inductor, a tap between the first and second portions of the secondary winding being connected to the reference end of the bridge circuit
Data Source
AI summary
A novel converter circuit topology is disclosed. The converter circuit has a bridge circuit, a transformer, and a half-bridge current-doubler rectifier. An input end of the bridge circuit is connected to an input voltage node of the converter circuit. A reference end of the bridge circuit is connected to an output voltage node of the converter circuit. Opposing ends of a primary winding of the transformer are connected to bridge nodes of the bridge circuit. A secondary winding of the transformer serves as current-doubler inductors of the half-bridge current-doubler rectifier. A tap of the secondary winding is connected to the reference end of the bridge circuit.