Single Inductor Full-Bridge DC-DC Converter

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Solution Overview

Problem

Current DC-DC converters are inefficient due to persistent DC current, leading to overheating in switches, and require multiple inductors, which occupy space and cause thermal issues.

Innovation Solution

A power electronic device with a single inductor configured to have symmetrical switching modes, resulting in a net DC component of approximately zero, allowing for a more compact and efficient converter with fewer components, suitable for low and medium voltage settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple inductors are used in DC-DC converter, then power conversion function is achieved, but device complexity and space occupation increase

Engineering Contradiction:

Improvepower conversion functionVSAvoidnumber of inductors

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple inductor functions into a single inductor by using a full-bridge converter topology where the inductor serves multiple purposes in the power conversion process. The single inductor L1 replaces what would traditionally require multiple inductors, reducing component count while maintaining the power conversion function through coordinated switching of four switches (S1-S4).

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single inductor L1 performs multiple functions simultaneously: it stores energy, transfers power, and enables bidirectional current flow. The full-bridge converter topology allows the same inductor to serve different roles during different switching phases, achieving multi-functionality with a single component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple inductors are used in DC-DC converter, then power conversion is achieved, but weight increases

Engineering Contradiction:

Improvepower conversion functionVSAvoidconverter weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent merges multiple inductor components into a single inductor L1, directly reducing the total weight of the converter. By eliminating redundant inductors and using one inductor to perform multiple functions through the full-bridge topology, the overall weight of the power conversion device is significantly reduced.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If DC current persists in inductor, then power conversion operates, but thermal stress and overheating occur

Engineering Contradiction:

Improvepower conversion operationVSAvoidinductor temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent employs periodic switching action with a symmetrical full-bridge converter topology that causes the inductor current to alternate direction periodically. The controller switches the four switches (S1-S4) in a coordinated periodic manner, creating alternating current flow through the inductor that prevents DC bias and reduces thermal stress through regular current reversal.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent inverts the traditional unidirectional current flow by implementing bidirectional current flow through the inductor. The full-bridge converter topology allows current to flow in opposite directions during different switching phases, effectively canceling out any DC component and preventing the thermal issues associated with persistent DC current.

Inventive Principle:

Principle #13The other way round (Inversion)

4Reliability

If multiple inductors are used in DC-DC converter, then power conversion is achieved, but space occupation increases

Engineering Contradiction:

Improvepower conversion functionVSAvoidconverter volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent merges multiple inductor components into a single inductor L1, directly reducing the volume occupied by magnetic components. This consolidation eliminates the space required for multiple separate inductors while maintaining power conversion functionality through the full-bridge converter topology and coordinated switching control.

Inventive Principle:

Principle #5Merging (Combining)

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 reduces space, weight, electrical losses, and component count, improving protection and power quality while reducing electromagnetic interference and thermal stresses, making it more affordable and reliable.

Implementation Method 1

at least one inductor configured to couple to a first capacitor and a second capacitor... the first and second currents interact with each other through the inductor

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10137788B2Power electronic device and method

Publication Date: 2018.11.27 GENERAL ELECTRIC CO

AI summary

A power electronic device includes at least one inductor configured to couple to a first capacitor and a second capacitor. The power electronic device includes a controller configured to control a first current conducting through the inductor and a second current conducting through the inductor. The first and second currents conduct in opposite directions with respect to each other, and the first and second currents interact with each other through the inductor such that a net direct current (DC) component through the inductor is approximately zero.