Multi-Phase DC/DC Converter Topology With Fewer Blocking Capacitors
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Solution Overview
Problem
Existing isolated multi-phase DC/DC converters require multiple blocking capacitors to prevent transformer saturation, leading to increased cost and reduced power density due to the need for multiple capacitor banks in high power applications.
Innovation Solution
The proposed solution reduces the number of blocking capacitors by utilizing the fact that the current in one phase is the sum of currents in other phases, allowing for the elimination of one blocking capacitor bank at the primary and secondary sides of the multi-phase transformer, thereby achieving cost-effectiveness and higher power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple blocking capacitors are used in each phase to prevent transformer saturation, then transformer saturation is prevented, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the blocking capacitor functions across multiple phases by connecting capacitors in series between phases rather than placing separate capacitors in each phase. This reduces the total quantity of blocking capacitors while maintaining the function of preventing transformer saturation through inter-phase voltage balancing.
Solution Approach 2:
The blocking capacitors are designed to serve multiple phases simultaneously through series connections. Each capacitor contributes to preventing saturation for multiple phases, making the capacitor bank a multi-functional component that reduces overall device complexity.
2Reliability
If multiple blocking capacitors are used in each phase to prevent transformer saturation, then transformer saturation is prevented, but power density decreases
Solution Approach 1:
By merging capacitor functions across phases through series connections, the total volume of capacitor materials required is reduced. This increases the ratio of useful power processing components to supporting components, thereby improving power density.
3Ease of manufacture
If blocking capacitors are eliminated to reduce cost and complexity, then cost effectiveness improves, but transformer saturation control may be compromised
Solution Approach 1:
The patent achieves cost reduction by merging capacitor functions across phases, reducing the total number of capacitors required. This lower component count directly reduces manufacturing cost while the series inter-phase connection topology maintains saturation prevention capability.
Solution Approach 2:
The inter-phase series capacitor connection creates a self-balancing system where the capacitors automatically maintain voltage balance across phases without additional control circuitry. This self-service mechanism ensures reliable saturation prevention while minimizing component requirements.
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 approach reduces the number of electronic components and manufacturing costs while maintaining reliable operation by ensuring that the DC component of the magnetizing current is zero, thus preventing transformer saturation without additional control measures.
Implementation Method 1
a third quantity of blocking capacitors, each being electrically connected in series to a respective one of the terminals of the primary circuit; and a fourth quantity of blocking capacitors, each being electrically connected in series to a respective one of the terminals of the secondary circuit
Implementation Method 2
a multi-phase transformer having a primary circuit and a secondary circuit magnetically coupled to the primary circuit
Data Source
AI summary
The present disclosure provides an isolated multi-phase DC/DC converter with a reduced quantity of blocking capacitors. In one aspect, the converter includes a multi-phase transformer having a primary circuit and a secondary circuit magnetically coupled to the primary circuit, the primary circuit having a first quantity of terminals, and the secondary circuit having a second quantity of terminals; a third quantity of blocking capacitors, each being electrically connected in series to a respective one of the terminals of the primary circuit; and a fourth quantity of blocking capacitors, each being electrically connected in series to a respective one of the terminals of the secondary circuit. The third quantity is one less than the first quantity. The fourth quantity is one less than the second quantity.