Modular SiC Power Converter With Integrated EMI Filtering

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Solution Overview

Problem

Conventional power converters face challenges in providing scalable power while minimizing losses and heat generation, especially in high-power applications that require efficient conversion between DC and AC power.

Innovation Solution

The multi-purpose power converter is designed to be modular and scalable, eliminating the need for line filter reactors and charging resistors, and incorporating advanced edge computing for condition monitoring and energy storage using supercapacitors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If high-frequency switching is used for power conversion in high-power applications, then power conversion capability is improved, but power losses and heat generation increase

Engineering Contradiction:

Improvepower conversion capabilityVSAvoidpower losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent changes the switching frequency parameter from conventional high-frequency operation to a lower frequency range, specifically optimizing the switching frequency to reduce switching losses while maintaining adequate power conversion capability. This parameter optimization directly addresses the contradiction by finding a frequency sweet spot that balances conversion efficiency with loss minimization.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If conventional power converter components (line filter reactor, charging resistor) are included, then electromagnetic interference filtering is improved, but device size and complexity increase

Engineering Contradiction:

Improveelectromagnetic interferenceVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the functions of the line filter reactor and charging resistor into the main power converter circuit topology. By integrating these filtering and protection functions directly into the converter's switching architecture, the design eliminates the need for separate discrete components, thereby reducing overall device size and complexity while maintaining electromagnetic interference filtering capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power converter circuit is designed to perform multiple functions simultaneously: power conversion, electromagnetic interference filtering, and inrush current limiting. This multi-functionality is achieved through a universal circuit topology that incorporates reactive elements serving dual purposes, eliminating the need for dedicated separate components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If modular and scalable converter design is implemented, then adaptability to different applications is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveapplication scalabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The power converter is designed as a modular system with distinct functional blocks that can be independently manufactured and assembled. The converter features standardized interface connections between modules, allowing different combinations of modules to be configured for various power levels and application requirements. This segmentation enables scalable deployment from single-module to multi-module configurations without requiring custom manufacturing for each application.

Inventive Principle:

Principle #1Segmentation

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 solution reduces power losses, minimizes conducted emissions, and achieves a smaller size for the conversion package, while also enhancing operational flexibility and electromagnetic compatibility.

Implementation Method 1

the power converter logic maximizes the stabilization by using an internal capacitor bank as an intermediate buffer for the energy

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 2

Conversions in high- power applications typically involve high frequency switching, generating significant heat and creating undesirable losses

Methodology Applied

Scientific EffectHigh-frequency switching:

Implementation Method 3

an integrated output filter of the power converter limits the rate of change of voltage (dv/dt) and allows for operation of regular peripheral components

Methodology Applied

Scientific EffectElectromagnetic filtering:

Data Source

PatentUS20250132694A1Multi-purpose power converter

Publication Date: 2025.04.24 AMETRADE INC

AI summary

Embodiments of the disclosure relate to a bi-directional power converter. The power converter includes first connectors configured to receive or transmit electrical energy at a first current, a first voltage, and/or a first current form and second connectors configured to receive or transmit electrical energy at a second current, a second voltage, and/or a second current form. The power converter also includes a controller and a plurality of SiC-based transistors in electrical communication with the first connectors and with the second connectors. The controller is configured for switching, using pulse width modulation, the plurality of SiC-based transistors to change the first current, the first voltage, and/or the first current form to the second current, the second voltage, and/or the second current form. The switching is at a frequency up to 50 KHz.