Serial Input Power Converter for Datacenter Voltage Conversion
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Solution Overview
Problem
Conventional power converter topologies in datacenters are inefficient when converting high voltage DC power to low voltage DC power required by CPU servers, leading to increased I2R power losses and thermal inefficiencies, especially when multiple stages of conversion are involved.
Innovation Solution
A system comprising multiple power converter stages with switching elements and transformers that electromagnetically couple primary and secondary sides, allowing for efficient conversion of higher voltage DC power (such as 48V DC) directly to a voltage appropriate for CPUs (around 1.7-1.8V DC) in a single stage, reducing voltage stress on switching elements and using current sharing and voltage balance control to optimize power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional multi-stage power conversion is used to convert high voltage DC to low voltage DC, then voltage transformation can be achieved, but I2R power losses increase and thermal inefficiencies worsen
Solution Approach 1:
The patent merges multiple power conversion stages into a single integrated converter that directly converts high voltage DC (e.g., 48V) to low voltage DC (e.g., 1.7-1.8V) in one step. This eliminates the need for intermediate conversion stages, thereby reducing cumulative I2R losses and improving overall system efficiency while maintaining manageable device complexity through unified design
2Temperature
If multiple stages of power conversion are employed, then voltage transformation is possible, but thermal inefficiencies increase
Solution Approach 1:
By combining multiple conversion stages into a single direct conversion architecture, the patent reduces the number of power electronic components and interconnections required. This minimizes the generation of heat at each stage and reduces thermal management complexity, thereby improving thermal efficiency without significantly increasing overall device complexity
3Quantity of substance
If high voltage DC power is converted through multiple stages, then power delivery can be achieved, but thicker and more expensive power cables are required
Solution Approach 1:
The patent changes the voltage parameter by implementing direct high-voltage-to-low-voltage conversion in a single stage, which reduces the current required for power delivery. This parameter change allows the use of thinner, less expensive power cables since the reduced current lowers the requirements for cable cross-sectional area while maintaining adequate power delivery capability
4Use of energy by moving object
If conventional power converter topologies are used, then power conversion can be performed, but efficiency decreases
Solution Approach 1:
The patent employs a modular converter topology with multiple parallel power conversion modules, each handling a portion of the total power. This segmentation allows for optimized component selection and operation in each module, improving overall conversion efficiency while keeping individual module complexity manageable. The modular approach also facilitates better thermal management and fault tolerance
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 I2R power losses, minimizes thermal inefficiencies, and allows for thinner, less expensive power cables while maintaining high efficiency and power density, compared to conventional multi-stage conversion methods.
Implementation Method 1
each power converter stage comprising a transformer that electromagnetically couples a primary side and a secondary side of the power converter stage
Data Source
AI summary
An apparatus includes first and second power converter stages, each stage having a primary side and a secondary side. The primary side of the first stage includes a switch T1A coupled to a voltage source and a switch T3A coupled to the switch T1A. The primary side of the second stage includes a switch T2A coupled to the switch T3A and a switch T4A coupled to the switch T3A and to the voltage source. The apparatus includes a control circuit to control an on/off time of the switches. The control circuit includes four gate driver controllers to control the on/off time of the switches and a current sharing control section to increase or decrease the on time of a switch based on a comparison of a current through one of multiple output inductors to an average current through the multiple output inductors.