LLC Converter Voltage Adaptation via PFC Input Control
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Solution Overview
Problem
Conventional LLC topology power supplies are inefficient in providing multiple output voltages, which is necessary for devices with USB-C ports, as they require additional DC-to-DC converters that reduce efficiency and increase complexity and cost, failing to comply with DOE efficiency regulations.
Innovation Solution
A modified LLC topology power supply using Active Power Factor Correction (PFC) to generate a variable high voltage input for the LLC converter, allowing it to efficiently provide multiple output voltages ranging from 5V to 20V by adjusting the PFC converter output voltage, thereby eliminating the need for additional DC-to-DC converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional LLC topology power supplies use additional DC-to-DC converters to provide multiple output voltages, then the power supply can support multiple devices with different voltage requirements, but the efficiency decreases and complexity increases
Solution Approach 1:
The patent changes the operating parameters of the LLC converter by dynamically adjusting the frequency of the AC waveform applied to the primary winding. By varying the frequency, the transformer can deliver different output voltages (5V, 12V, 15V, 20V) without requiring additional DC-to-DC converters, thus maintaining high efficiency while providing multiple voltage outputs.
Solution Approach 2:
The system dynamically adjusts the operating frequency of the LLC converter based on the required output voltage. The controller monitors the power profile from the USB-C IC and real-time power demands, then dynamically changes the frequency parameter to match the required voltage output, enabling a single converter to adapt to multiple voltage requirements efficiently.
2Adaptability or versatility
If conventional LLC topology power supplies use additional DC-to-DC converters to provide multiple output voltages, then the power supply can support multiple devices with different voltage requirements, but the device complexity and cost increase
Solution Approach 1:
The patent makes the LLC converter universal by enabling it to perform multiple functions - delivering different voltage levels (5V, 12V, 15V, 20V) using a single converter design. The controller adapts the converter's operating parameters to match different power profiles and device requirements, eliminating the need for multiple specialized converters and reducing overall system complexity.
Solution Approach 2:
The patent merges the functions of multiple DC-to-DC converters into a single LLC converter by combining different voltage delivery capabilities into one unified power conversion stage. This consolidation reduces the number of components, simplifies the power supply architecture, and lowers cost while maintaining the ability to serve multiple device types.
3Loss of energy
If conventional LLC topology power supplies are designed for single voltage output, then the efficiency is high, but they cannot comply with DOE efficiency regulations for multiple voltage outputs
Solution Approach 1:
The patent maintains high efficiency while providing multiple voltage outputs by changing the frequency parameter of the LLC converter rather than adding conversion stages. Each voltage output (5V, 12V, 15V, 20V) is achieved by operating the same converter at different frequencies, avoiding the efficiency losses associated with cascaded DC-to-DC conversion while meeting DOE regulations for multi-voltage capability.
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 enables a single power supply to efficiently provide multiple voltages, maintaining high efficiency and compliance with DOE regulations, while simplifying manufacturing and inventory for device manufacturers by avoiding the use of inefficient DC-to-DC converters.
Implementation Method 1
A power factor correction (PFC) converter may provide an output voltage that varies based on the power profile
Implementation Method 2
The LLC converter may produce an output voltage that varies in voltage level proportionally to the PFC converter output voltage
Data Source
AI summary
As an example, a power supply may provide a particular voltage of multiple voltages based on a power profile provided by a universal serial bus Type C (USB-C) integrated circuit (IC) built-in to a USB-C port of a computing device. A power factor correction (PFC) converter may provide an output voltage that varies according to the power profile. The output voltage of the PFC converter may be used as an input to an inductor-inductor-capacitor (LLC) converter. The LLC converter may produce an output voltage that varies in voltage level proportionally to the PFC converter output voltage. The PFC converter may provide a voltage to the LLC converter that causes the LLC converter to provide an amount of voltage indicated in the power profile sent by the USB-C IC of the computing device.