Integrated Magnetics Current Multiplier Rectifier Power Converter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current power converter topologies are inadequate for high-current applications at low to moderate voltages, as they suffer from poor power density, efficiency, and reliability due to increased component count, interconnect losses, and detrimental effects of fringing flux, which are not effectively addressed by existing multiphase interleaved current multiplier designs.
Innovation Solution
A power converter topology incorporating a switching circuit with multiple active phase legs, a magnetic device with integrated primary and secondary windings, and a current multiplier rectifier, which employs a phase-shifted full bridge configuration and matrix integrated magnetics to achieve higher interleaving levels without component replication, reducing switching ripple and core losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple discrete E-cores are used to implement multiphase interleaved current multiplier power converters, then higher current handling capability is achieved, but component count and interconnect losses increase, resulting in poor power density and efficiency
Solution Approach 1:
The patent combines multiple discrete E-cores into a single integrated magnetic core structure that accommodates multiple phases of the interleaved current multiplier converter. This integration reduces the number of separate magnetic components and interconnections, thereby lowering component count, reducing interconnect losses, and improving both power density and efficiency while maintaining the ability to handle high currents through multiphase operation
2Loss of energy
If windings are placed at a safe distance from the air gap to reduce fringing flux effects, then eddy current losses are reduced, but core window area utilization becomes poor
Solution Approach 1:
The patent applies different winding placement strategies for different phases within the integrated magnetic core. By optimizing the local positioning of windings relative to air gaps in each phase section, the design reduces fringing flux effects and eddy current losses in critical areas while maximizing the utilization of the overall core window area through efficient spatial arrangement of multiple phases
3Loss of energy
If a larger output capacitor is used to reduce output ripple voltage, then ripple voltage is reduced, but volume and weight increase and transient response becomes sluggish
Solution Approach 1:
The patent divides the output filtering function across multiple phases in the interleaved current multiplier converter. By segmenting the current delivery into multiple interleaved phases, the ripple frequency is increased and ripple amplitude is reduced, allowing for smaller output capacitance. This segmentation approach achieves low ripple voltage output while maintaining fast transient response and minimizing the weight and volume of the power converter
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
This solution enhances power density, efficiency, and reliability by reducing switching ripple, core losses, and the need for output filtering, while allowing for smaller, lighter components and faster transient responses to dynamic load conditions.
Implementation Method 1
a magnetic device with integrated primary and secondary windings
Implementation Method 2
a current multiplier rectifier
Data Source
AI summary
A power converter having input and output nodes and a method of operating the same. In one embodiment, the power converter includes a switching circuit including first, second and third active phase legs. Each of the first, second and third active legs includes a first switch coupled to one of the input nodes and a second switch coupled to another of the input nodes and has a common switching node therebetween. The power converter further includes a magnetic device including first, second and third primary windings, and first, second and third secondary windings. The first, second and third primary windings are coupled to the common switching node of the first, second and third active phase legs, respectively. The power converter still further includes a rectifier including first, second and third rectifier elements interposed between the first, second and third secondary windings, respectively, and one of the output nodes.