Single-Stage Isolated DC-DC Converter With Interleaved Arms
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Solution Overview
Problem
Conventional two-stage power conversion solutions for point of load (POL) applications are limited by complex circuitry, which results in reduced power density, efficiency, and increased expense, and struggle to meet the demands of wide input and output operational ranges.
Innovation Solution
A single-stage isolated DC-DC converter integrating a buck-boost circuit and a rectifier circuit with interleaved arms and a center-tapped inductor, allowing for soft switching and symmetrical AC output, which reduces component size and enhances power density and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional two-stage power conversion solutions are used, then voltage conversion capability is achieved, but device complexity increases and power density decreases
Solution Approach 1:
The patent combines the voltage conversion function and isolation function into a single integrated converter stage, eliminating the need for separate two-stage conversion. The single-stage converter incorporates both buck and boost capabilities along with galvanic isolation, reducing overall device complexity while maintaining high power density through unified circuit architecture.
Solution Approach 2:
The single-stage converter is designed to perform multiple functions simultaneously: voltage step-up, voltage step-down, galvanic isolation, and soft switching. This multi-functional integration eliminates the need for separate dedicated circuits for each function, thereby reducing device complexity while preserving power density.
2Ease of manufacture
If conventional two-stage power conversion solutions are used, then voltage conversion is achieved, but manufacturing cost increases
Solution Approach 1:
By merging multiple conversion stages into a single integrated converter, the patent reduces the total number of components that need to be manufactured and assembled. This consolidation simplifies the manufacturing process, reduces assembly steps, and lowers overall manufacturing cost while maintaining the required voltage conversion capabilities.
Solution Approach 2:
The single-stage converter's multi-functional design allows a single device to replace multiple specialized components, reducing the bill of materials and simplifying supply chain management. This universality directly translates to lower manufacturing costs through reduced component count and simplified production processes.
3Object-affected harmful factors
If conventional power conversion is used, then power sources with different voltage levels are matched, but noise is introduced
Solution Approach 1:
The patent employs soft switching techniques that convert what would traditionally be hard switching noise into controlled, minimized electromagnetic interference. By utilizing resonant soft switching, the converter achieves zero-voltage or zero-current switching transitions, transforming potential noise-generating events into beneficial soft transitions that reduce EMI while maintaining efficient power conversion.
4Temperature
If conventional power conversion is used, then voltage level matching is achieved, but thermal load increases
Solution Approach 1:
The soft switching mechanism converts hard switching losses into minimal switching losses by utilizing resonant transitions. This transforms what would be thermal-generating hard switching events into efficient soft transitions, significantly reducing thermal load while preserving the converter's ability to handle wide voltage ranges and maintain high power conversion capability.
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 single-stage converter achieves increased power density, efficiency, and wide-range voltage gain, facilitating high power density and wide-ranging voltage conversion ratios, making it suitable for applications like electric vehicle charging and POL power supplies.
Implementation Method 1
an inductor operable to generate an AC output to the rectifier
Implementation Method 2
rectifying the AC voltage with an LLC resonant circuit
Implementation Method 3
rectifying the AC voltage with an LLC resonant circuit of the converter and at least one diode of the converter
Data Source
AI summary
According to one aspect of the present disclosure, a single-stage converter includes a rectifying circuit and a buck-boost circuit. The buck-boost circuit includes an inductor with a center tap configured to supply an output of the buck-boost circuit to the rectifying circuit. The buck-boost circuit also includes first and second interleaved arms arranged in parallel with a voltage input of the single-stage converter. The first and second interleaved arms are each coupled to the inductor and include a plurality of switches operable to control the output of the buck-boost circuit.