Power Conversion Module Topology for 48V-to-2.2V Dynamic Response
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Solution Overview
Problem
Existing power conversion modules face inefficiencies and limitations in achieving high power density and dynamic properties when using two-stage converters or single-stage converters with large output inductors, particularly with input voltages of 48V and output voltages of 2.2V.
Innovation Solution
A power conversion module with a voltage reduction function, incorporating a transformer with parallel bridge arms and rectifying circuits, reduces input voltage from 48V to 2.2V while enhancing efficiency and reducing volume, utilizing MOSFET or GaN switches and integrated magnetic elements to minimize inductance and parasitic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single-stage converter with an integrated magnetic element is used, then conversion efficiency and power density are improved, but the inductance of the output inductor becomes large and dynamic properties deteriorate
Solution Approach 1:
The patent divides the single-stage converter into two separate stages: a first stage (half-bridge current-doubling rectifier) and a second stage (voltage reduction circuit). This segmentation allows each stage to be optimized independently - the first stage achieves high conversion efficiency and power density, while the second stage provides low inductance for improved dynamic properties and load response
2Power
If a single-stage converter with an integrated magnetic element is used, then power density is improved, but the inductance of the output inductor becomes large
Solution Approach 1:
The patent segments the power conversion function into two independent circuits with separate magnetic elements. The first stage uses an integrated magnetic element for high power density, while the second stage uses a separate output inductor with optimized (lower) inductance value to meet dynamic response requirements
Solution Approach 2:
The patent introduces an intermediate voltage node between the two stages, where the first stage outputs a higher voltage that is then reduced by the second stage. This intermediary approach allows the system to achieve both high power density in the first stage and low inductance in the second stage, resolving the contradiction between power density and inductance
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 module achieves low output ripple, small volume, high efficiency, and simplified applications by effectively converting high input voltage to low output voltage, with improved load dynamic response and reduced inductor size.
Implementation Method 1
The transformer includes a primary winding, a first secondary winding and a second secondary winding
Implementation Method 2
The first rectifying circuit includes a first rectifying switch, a second rectifying switch and a first output inductor
Data Source
AI summary
A power conversion module includes a first bridge arm, a second bridge arm, a transformer and a rectifying circuit. An output positive terminal and an output negative terminal are electrically connected with a low-voltage and high-current load. The first bridge arm and the second bridge arm are electrically connected between an input positive terminal and an input negative terminal. The transformer includes a primary winding, a first secondary winding and a second secondary winding. The two terminals of the primary winding are electrically connected with a midpoint of the first bridge arm and a midpoint of the second bridge arm. An output inductor of the rectifying circuit is electrically connected between the winding midpoint and the output positive terminal. The input voltage is higher than 40V. The output voltage is lower than or equal to 2.2V.