SEPIC Synchronous Rectifier Drive Switching for Wide Output Voltage

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Solution Overview

Problem

Existing DC/DC converters face limitations in generating stable output voltage when the output voltage exceeds the drive voltage, leading to restricted output voltage settings and difficulty in high-speed switching operations required for automotive applications, especially due to large gate-to-source capacitance and excessive switching losses in P-channel MOSFETs.

Innovation Solution

A DC/DC converter with a drive voltage switching circuit that dynamically switches between using the drive voltage and output voltage to power the drive circuit, allowing for optimal power supply regardless of voltage magnitude, and integrating the drive circuit and switching components on a single semiconductor substrate, enabling efficient high-speed switching operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the drive voltage is set lower than the output voltage, then the P-channel MOSFET can be driven off completely, but the drive circuit cannot obtain sufficient drive voltage to switch the MOSFET off when output voltage exceeds drive voltage

Engineering Contradiction:
ImproveMOSFET off-state drive capabilityVSAvoidoutput voltage range
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies dynamics by making the drive voltage source selectable rather than fixed. The drive circuit can dynamically switch between two power supply sources: the drive voltage (VDRV) when output voltage is low, and the output voltage (VO) when it exceeds the drive voltage. This dynamic adaptability resolves the contradiction by allowing the system to maintain reliable MOSFET off-state drive capability across the entire output voltage range.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The drive circuit is designed with multi-functionality to operate under different voltage conditions. By incorporating a drive voltage selection mechanism that can universally handle both drive voltage and output voltage as power sources, the circuit maintains its ability to drive the P-channel MOSFET off completely regardless of whether the output voltage is lower or higher than the drive voltage, thus expanding the adaptable output voltage range.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Device complexity

If a resistor is used in the off-drive side of the output stage circuit, then the circuit is simple, but the gate-to-source capacitance cannot be discharged at high speed

Engineering Contradiction:
Improvedrive circuit structureVSAvoidswitching speed
Core Design Contradiction:
Device complexityVSSpeed

Solution Approach 1:

The patent merges the drive circuit and switching components onto a single semiconductor substrate. This integration allows for optimized signal paths and reduced parasitic elements, enabling high-speed discharge of the gate-to-source capacitance while maintaining circuit simplicity. The integrated design eliminates the need for external resistors in the off-drive path, achieving both low complexity and high switching speed.

Inventive Principle:
Principle #5Merging (Combining)

3Speed

If the gate resistance is made small to speed up switching operation, then the switching speed increases, but the loss of the gate resistance becomes excessive

Engineering Contradiction:
Improveswitching speedVSAvoidgate resistance loss
Core Design Contradiction:
SpeedVSLoss of energy

Solution Approach 1:

The patent optimizes the gate resistance parameter by integrating the drive circuit on the same semiconductor substrate as the switching components. This integration allows for precise control and optimization of the gate resistance value, achieving a balance where the resistance is low enough to enable high-speed switching (up to 2 MHz) but not so low that excessive power loss occurs. The integrated design enables parameter optimization that cannot be achieved with discrete external components.

Inventive Principle:
Principle #35Parameter changes

4Productivity

If the drive circuit and switching components are integrated on a single semiconductor substrate, then the switching speed increases, but the manufacturing complexity increases

Engineering Contradiction:
Improveswitching operation frequencyVSAvoidcircuit integration
Core Design Contradiction:
ProductivityVSEase of manufacture

Solution Approach 1:

The patent merges the drive circuit and switching components onto a single semiconductor substrate, achieving high-speed switching operations up to 2 MHz. While integration inherently increases manufacturing complexity, the patent addresses this by using standard semiconductor fabrication processes and designing the integrated circuit with manufacturability in mind, balancing the trade-off between performance and ease of manufacture.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS12003180B2Power supply for driving synchronous rectification elements of SEPIC converter
Publication Date: 2024.06.04 SANKEN ELECTRIC CO LTD
  • US12003180B2 patent drawing
  • US12003180B2 patent drawing
  • US12003180B2 patent drawing

AI summary

A DC-DC converter according to one or more embodiments is disclosed that may include: a drive voltage switching circuit of a drive circuit that drives a synchronous rectification MOS transistor. The drive voltage switching circuit may switch a connection so that the drive circuit supplies power from the output voltage to the drive circuit in response to the drive voltage for supplying power to the drive circuit being set to be lower than the output voltage. The drive voltage switching circuit may switch a connection so that the drive circuit supplies power from the drive voltage in response to the drive voltage for supplying power to the drive circuit being set to be higher than the output voltage.