Power Conversion System with Dynamic Synchronous Rectification
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Solution Overview
Problem
Power conversion systems using diodes and Schottky diodes experience significant power loss due to their forward bias, and existing synchronous rectifier systems face inefficiencies, especially under light load conditions, as they provide constant power regardless of load conditions, leading to increased losses.
Innovation Solution
A power conversion system incorporating a switching module, resonant module, and integrated power-converting module with a primary winding, parallel power-converting units, and a magnetic core, utilizing synchronous rectifying units and a controller to manage power delivery based on load conditions, minimizing power loss by optimizing the operation of MOSFETs and adjusting the number of synchronous rectifying units and coupling distances to control leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If synchronous rectifiers are driven at the same time to rectify power, then the rectifying capability is improved, but the power loss increases under light load conditions
Solution Approach 1:
The patent applies dynamics by making the synchronous rectifier system adjustable based on load conditions. The controller dynamically controls the switching of MOSFETs in the synchronous rectifiers, enabling the system to adapt its power delivery to match actual load requirements rather than operating at constant power. This resolves the contradiction by allowing full rectifying capability when needed while reducing power loss during light load conditions.
Solution Approach 2:
The patent changes operational parameters by adjusting the switching states of MOSFETs based on detected load conditions. When the load condition indicates light power demand, the controller modifies the switching parameters of the synchronous rectifiers to reduce power delivery accordingly. This parameter adjustment resolves the contradiction between maintaining rectifying capability and minimizing power loss under varying load conditions.
2Stability of the object's composition
If constant power is provided regardless of load conditions, then the power supply stability is improved, but the power loss increases under light load conditions
Solution Approach 1:
The patent implements feedback by detecting the actual load condition and using this information to control the power delivery from synchronous rectifiers. The controller continuously monitors load status and adjusts the MOSFET switching accordingly, creating a closed-loop system that maintains power supply stability while adapting to actual demand. This feedback mechanism resolves the contradiction by eliminating constant power delivery and instead providing stable, demand-appropriate power supply.
3Device complexity
If diodes or Schottky diodes are used for rectification, then the circuit simplicity is improved, but the power loss increases due to forward bias
Solution Approach 1:
The patent substitutes passive diode-based rectification with active MOSFET-based synchronous rectification controlled by electronic switching signals. Instead of relying on the passive forward bias characteristics of diodes, the system uses electronically controlled MOSFETs that can be switched on and off precisely. This substitution resolves the contradiction by accepting increased circuit complexity in exchange for dramatically reduced power loss, as MOSFETs have much lower conduction losses when properly controlled.
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 system reduces power loss during light load conditions and improves efficiency by dynamically adjusting power delivery based on load requirements, ensuring lower electromagnetic interference and higher efficiency across varying load conditions.
Implementation Method 1
The magnetic conversion module includes a primary winding and a PCB winding module
Implementation Method 2
a resonant module
Data Source
AI summary
A power conversion system is provided. The system includes a switch module, a resonant module, a magnetic conversion module, a bobbin and an iron core. The magnetic conversion module includes a primary winding and a PCB winding module. The PCB winding module includes a printed circuit board, a conductive layer disposed on at least one surface of the printed circuit board, and a switch unit disposed on the printed circuit board.