Power Conversion Module With Full-Bridge Circuit
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Solution Overview
Problem
Conventional power conversion modules with half-bridge circuit architectures face limitations such as narrow voltage gain range, low transformer turn ratio, high primary side current, high stress on synchronous rectifying elements, and low conversion efficiency when converting input voltages between 36V and 75V to 12V or 5V outputs.
Innovation Solution
A power conversion module utilizing a full-bridge switching circuit, magnetic device with coupled winding pairs, and an energy storage capacitor set, which allows for a broader voltage gain range, reduced primary side current, and enhanced conversion efficiency by enabling a maximum duty cycle greater than 0.5, thereby reducing stress on rectifying elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a half-bridge circuit architecture is used, then the device complexity is reduced, but the voltage gain range becomes narrow and conversion efficiency decreases
Solution Approach 1:
The patent divides the single half-bridge circuit into two separate half-bridge circuits operating in parallel. Each half-bridge circuit handles a portion of the power conversion, allowing independent optimization of each circuit's duty cycle. This segmentation enables the overall system to achieve a broader voltage gain range while maintaining manageable device complexity through modular architecture.
2Reliability
If the maximum duty cycle is limited to 0.5 to avoid arm-shot, then device reliability is improved, but the voltage gain range becomes narrow and primary side current increases
Solution Approach 1:
By dividing the power conversion into two parallel half-bridge circuits, each circuit can operate with a duty cycle within the safe 0-0.5 range to avoid arm-shot, while the combined effect of both circuits achieves the desired broader voltage gain range. This segmentation allows reliability to be maintained in each individual circuit while achieving adaptability at the system level.
Solution Approach 2:
The patent merges the output of two parallel half-bridge circuits to achieve the desired voltage gain range. Each circuit operates independently with duty cycles limited to 0.5 for reliability, but their combined output provides the broader voltage gain capability that would be impossible with a single circuit constrained by the same duty cycle limit.
3Device complexity
If the transformer turn ratio is reduced to accommodate duty cycle limits, then device complexity is simplified, but the primary side current increases and stress on rectifying elements increases
Solution Approach 1:
The patent segments the power handling into two parallel transformer circuits, allowing each transformer to operate with a moderate turn ratio optimized for its specific duty cycle range. This segmentation prevents the need for extreme turn ratios in a single transformer, reducing primary side current while maintaining simplified device complexity through modular transformer design.
4Reliability
If the duty cycle is limited to 0.5, then arm-shot is avoided, but the stress on synchronous rectifying elements increases and conversion efficiency decreases
Solution Approach 1:
By dividing the power conversion into two parallel half-bridge circuits, each circuit can operate with optimized duty cycles within the safe range while sharing the rectifying element stress. This segmentation reduces the stress on individual synchronous rectifying elements compared to a single circuit operating at maximum duty cycle, thereby improving conversion efficiency while maintaining arm-shot avoidance.
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 provides a power conversion module with a broader voltage gain range, lower primary side current, and higher conversion efficiency, effectively addressing the limitations of conventional half-bridge architectures.
Implementation Method 1
The magnetic device includes a first coupled winding pair and a second coupled winding pair. The first coupled winding pair includes a first winding and a second winding. The second coupled winding pair includes a third winding and a fourth winding. The first winding and the second winding are coupled to each other. The third winding and the fourth winding are coupled to each other.
Data Source
AI summary
A power conversion module includes an input port, an output port, a full-bridge switching circuit, a magnetic device, an energy storage capacitor set and a rectifier circuit. The magnetic device includes a first coupled winding pair and a second coupled winding pair. The first coupled winding pair includes a first winding and a second winding, which are coupled to each other. The second coupled winding pair includes a third winding and a fourth winding, which are coupled to each other. The first winding and the third winding are connected between a first bridge arm and a second bridge arm of the full-bridge switching circuit. The energy storage capacitor set is electrically connected with the input port, and electrically connected with the first winding and the third winding. The rectifier circuit is electrically connected with the second winding, the fourth winding and the output port.